Welding Sensor Housing With Thermal Shield Gap for Accurate Detection
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Solution Overview
Problem
The existing sensor devices for welding face challenges in maintaining detection accuracy due to radiation heat transfer from welded workpieces, which can exceed the heat-resistant temperature of the sensor unit, causing thermal expansion and reduced durability.
Innovation Solution
A sensor device with a shielding member made of material with lower thermal conductivity than the housing case, attached on the rear face side of the housing case, reduces radiation heat transfer by forming a gap between the shielding member and the housing case, and using a ceramic material for the shielding member with an elastic member for shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding portion is formed integrally with the protective cover using the same material, then sputter sticking to the container is reduced, but radiation heat is transferred to the sensor unit causing thermal expansion and reduced detection accuracy
Solution Approach 1:
The shielding portion is separated from the protective cover into an independent shielding member that can be attached or detached. This segmentation allows the shielding member to block sputter while the gap between the shielding member and protective cover prevents heat transfer to the sensor unit, resolving the contradiction between sputter protection and heat isolation.
Solution Approach 2:
A gap is introduced as an intermediary space between the shielding member and the protective cover. This gap acts as a thermal barrier that prevents radiation heat from reaching the sensor unit while allowing the shielding member to remain in position for sputter protection, thus maintaining detection accuracy.
2Ease of manufacture
If the shielding portion is made of the same material as the protective cover, then manufacturing is simplified, but the sensor unit is heated above its heat-resistant temperature reducing durability
Solution Approach 1:
The shielding member is made as a separate component from the protective cover, allowing different material selections optimized for their respective functions. The shielding member can be made of material optimal for sputter resistance while the protective cover maintains its structural properties, and the gap between them provides thermal isolation to protect the sensor unit.
3Stability of the object's composition
If the shielding member is attached directly to the housing case, then structural stability is improved, but thermal conduction increases transferring heat to the sensor unit
Solution Approach 1:
A gap is maintained between the shielding member and the protective cover/housing case structure. This gap serves as a thermal barrier that interrupts heat conduction paths while the shielding member remains positioned to provide structural stability and sputter protection, thus preventing excessive heating of the sensor unit.
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 configuration effectively reduces the impact of radiation heat on the sensor unit, ensuring its accuracy and durability by minimizing heat transfer and providing shock absorption.
Implementation Method 1
a shielding member (5) made of a material with lower thermal conductivity than that of a housing case (3), and having formed therein a plate-like portion (51) extending so as to shield radiation heat generated from workpieces (W) while they are welded together
Implementation Method 2
forming a gap between the shielding member and the housing case
Implementation Method 3
providing shock absorption
Data Source
Figure 1
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Figure 3
AI summary
The durability and detection accuracy of a sensor unit may possibly decrease due to radiation heat generated from workpieces while they are welded together. A sensor device 1 includes a sensor unit 2, a housing case 3, and a shielding member 5. The sensor unit 2 is a device for measuring the shapes of the workpieces W or the distance to the workpieces W. The housing case 3 houses the sensor unit 2 and has formed therein a pass-through portion 36a for laser beam projection and a pass-through portion 36b for detection that pass a laser beam L1 from a laser beam projection unit 21 and a laser beam L2 directed to a detection unit 22, respectively. 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 made of a material with lower thermal conductivity than that of the housing case 3.