Welding Cable Sensor Connector With Inductive Power Isolation
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Solution Overview
Problem
Existing welding apparatuses face challenges in efficiently monitoring and tracking welding parameters such as voltage and current, while also ensuring that power is sourced from welding cables without disrupting the voltage signals necessary for arc ignition.
Innovation Solution
A connector and sensor unit that includes current sensor circuitry, voltage sensing circuitry, and supply power circuitry, which connects to welding cables via inductors to sense and monitor welding parameters and generate power for internal circuitry without interfering with the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If power is sourced directly from welding cables without isolation, then the connector and sensor unit can be powered, but the voltage signals necessary for arc ignition are disrupted
Solution Approach 1:
An inductor is introduced as an intermediary component between the welding cable and the connector/sensor unit power input. The inductor couples the high-frequency ignition voltage to the sensor unit while blocking the low-frequency welding current, thereby providing power to the sensor unit without disrupting the arc ignition signals.
Solution Approach 2:
The electrical connection is segmented into separate pathways: one for high-frequency ignition voltage (through the inductor to power sensors) and another for low-frequency welding current (through the welding cable to the welding process). This segmentation allows both functions to operate independently without interference.
2Loss of information
If welding parameters are monitored and tracked, then welding process visibility is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single integrated connector and sensor unit: power input from welding cables, current sensing, voltage sensing, and signal output are all combined in one device. This reduces the number of separate components needed while providing comprehensive welding parameter monitoring.
Solution Approach 2:
The connector and sensor unit is designed as a multi-functional device that simultaneously performs electrical connection, power distribution to internal circuitry, parameter sensing (both current and voltage), and signal transmission to external systems, eliminating the need for multiple separate devices.
3Reliability
If inductors are used to couple power without disrupting signals, then signal integrity is maintained, but energy loss increases
Solution Approach 1:
The inductor is designed to provide sufficient coupling for the high-frequency ignition voltage while accepting some energy loss, as the ignition voltage requires only partial power transfer. The inductor values are selected to be excessive for minimal power transfer needs, ensuring signal integrity while tolerating some energy dissipation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables effective monitoring and tracking of welding parameters, ensuring reliable arc ignition and maintaining the integrity of welding signals, while providing a stable power supply for the connector and sensor unit.
Implementation Method 1
supply power circuitry configured to generate a predetermined voltage for at least the current sensor circuitry, wherein the supply power circuitry receives power from at least one of the first welding cable and the second welding cable and via at least one inductor
Data Source
AI summary
A connector and sensor unit for a welding apparatus, including a first port configured to be connected to a first welding cable of the welding apparatus, a second port configured to be connected to a second welding cable of the welding apparatus, current sensor circuitry configured to sense a current being supplied by the first welding cable and the second welding cable, and to output a corresponding current sense signal, voltage sensing circuitry configured to sense a voltage between the first welding cable and the second welding cable, and to output a corresponding voltage sense signal, and supply power circuitry configured to generate a predetermined voltage for at least the current sensor circuitry, wherein the supply power circuitry receives power from the first welding cable and the second welding cable via at least one inductor.