Welding Sensor Housing With Gas Redirection for Shielding Purity
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Solution Overview
Problem
Existing sensor devices for welding can disrupt the flow of shielding gas during the welding process, causing active gases to mix into the welded portion, which affects the quality of the weld.
Innovation Solution
A sensor device with a shielding portion that redirects and cools the gas discharged from the outlet port, preventing it from interfering with the welding area by inclining the shielding portion to divert the gas flow away from the welding zone and using a gas flow channel to cool the radiation heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a gas flow channel discharges gas from the housing case, then fume generated during welding can be prevented from entering the housing case, but the discharged gas may flow toward the welding area and mix into the welded portion
Solution Approach 1:
The outlet port is positioned on the rear face of the housing case, utilizing the spatial dimension behind the housing to discharge gas. This directional change in gas discharge prevents the gas from flowing forward toward the welding area while still effectively preventing fume from entering the housing case through the gas flow channel.
2Object-generated harmful factors
If shielding portion is added to redirect gas flow, then gas can be blown to shielding portion and flow away from welding area, but device complexity increases
Solution Approach 1:
The shielding portion is designed to serve multiple functions: it shields the sensor unit from radiation heat generated during welding, and simultaneously acts as a surface to redirect the discharged gas flow away from the welding area. By combining these functions into a single component, the device complexity is minimized while achieving the desired gas flow control.
3Temperature
If gas flow channel is used to cool radiation heat, then shielding portion can be cooled, but energy consumption increases
Solution Approach 1:
The gas flowing through the gas flow channel serves a dual purpose: it prevents fume from entering the housing case and cools the shielding portion through convection as it passes along the channel. The gas flow essentially cools the shielding portion passively without requiring additional energy input, as the cooling function is provided by the gas flow already necessary for fume prevention.
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
This design reduces the influence of discharged gases on the welding area, ensuring stable and high-quality welds by preventing gas interference and maintaining a clean shielding environment.
Implementation Method 1
a shielding portion (5) adapted to shield radiation heat directed toward the housing portion (30) among radiation heat generated while the workpieces (W) are welded together
Implementation Method 2
a gas flow channel (35) that passes a gas... the shielding portion (5) is inclined with respect to a flow direction of a gas passing through an outlet port (37e)
Implementation Method 3
the shielding portion (5) is inclined with respect to a flow direction of a gas passing through an outlet port (37e) such that the gas discharged from the outlet port (37e) is blown to the shielding portion (5) and thus flows to a side opposite to the side where the workpieces (W) are to be welded together
Data Source
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AI summary
A gas, which flows between a welding device and workpieces while the workpieces are welded together, has large influence on the welding. A sensor device 1 includes a sensor unit 2 and a container 3A that includes a housing case (i.e., housing portion) 3 and a shielding member (i.e., shielding portion) 5. The shielding member 5 is attached to the housing case 3, and shields radiation heat directed toward the lower surface of the housing case 3 among radiation heat generated while the workpieces W are welded together. The shielding member 5 is inclined with respect to a flow direction of a gas passing through an outlet port 48b for detection of a second gas flow channel 47 so that the gas discharged from the outlet port 48b for detection is blown to the shielding member 5 and thus flows to a side opposite to the side where the workpieces W are to be welded together.