Welding Sensor Cover Venting for Stable Fume-Free Detection
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Solution Overview
Problem
The existing sensor device for welding faces instability in gas flow, leading to varying detection accuracy due to pulsating gas discharge, which can allow excessive fumes to enter the detection light beam path, affecting the measurement accuracy.
Innovation Solution
Incorporating an accumulator with vent holes between the protective cover and the case body to stabilize gas pressure and flow, ensuring stable discharge of gases and prevention of fume entry, thereby maintaining consistent measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If gas is discharged from the outlet port to prevent fume entry, then fume protection is improved, but gas flow stability deteriorates due to pulsation
Solution Approach 1:
The accumulator is positioned upstream in the gas flow path to cushion and stabilize the gas flow before it reaches the outlet port. This pre-stabilization prevents pulsation from affecting the detection light beam path, while still maintaining sufficient gas discharge to prevent fume entry.
Solution Approach 2:
The accumulator acts as an intermediary component between the gas source and the outlet port. It mediates the gas flow by absorbing pulsations and providing a stable, continuous flow that simultaneously protects against fumes and maintains detection accuracy.
2Object-affected harmful factors
If gas flow rate is increased to stabilize protection, then fume prevention is improved, but detection accuracy deteriorates due to excessive gas entering the light beam path
Solution Approach 1:
The gas flow is differentiated into two zones: a stabilized flow through the accumulator that maintains protection without excessive pulsation, and a controlled discharge at the outlet port that prevents fume entry while minimizing interference with the detection light beam path.
Solution Approach 2:
The accumulator cushions the gas flow upstream, creating a stable pressure foundation that allows for controlled, steady discharge at the outlet port. This prevents both fume entry and excessive gas interference with the detection system.
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 stabilizes gas flow and discharge, reducing foreign matter sticking to the protective cover and enhancing detection accuracy by ensuring a consistent gas flow and pressure, leading to improved welding quality.
Implementation Method 1
the gas flow channel has formed therein an accumulator between the protective cover and the case body, the accumulator being adapted to have accumulated therein a gas flowing through the gas flow channel
Implementation Method 2
the protective cover has formed therein a gas flow channel that passes a gas to be blown to the protective plate, the gas flow channel having formed therein an outlet port that passes the detection light beam
Data Source
AI summary
A sensor device includes a sensor to detect a light beam to measure states of work pieces or a distance to the work pieces, a case body housing the sensor, and a protective cover including a protective plate that transmits the detection light beam. The protective cover includes a gas flow channel that passes a gas to be blown to the protective plate, the gas flow channel having formed therein an outlet port that passes the detection light beam and discharges the gas having flowed through the gas flow channel. The gas flow channel includes an accumulator between the protective cover and the case body adapted to have accumulated therein the gas flowing through the gas flow channel, and the accumulator includes vent holes through which the gas is allowed to flow out toward the outlet port.