Welding Sensor Housing With Thermal Shielding 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 work pieces, which can exceed the heat-resistant temperature of the sensor unit, causing thermal expansion and reduced durability.
Innovation Solution
A sensor device design featuring a shielding member made of material with lower thermal conductivity than the housing case, strategically positioned to reduce radiation heat transfer to the sensor unit, and incorporating a gap or elastic member for enhanced heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding member is formed integrally with the protective cover and made of the same material, then sticking of sputter to the container is reduced, but radiation heat is transferred to the entire protective cover and sensor unit, causing thermal expansion and reduced detection accuracy
Solution Approach 1:
The shielding member is separated from the housing case structure, allowing independent material selection and positioning. This segmentation enables the shielding member to be made of a material with lower thermal conductivity than the housing case, reducing heat transfer to the sensor unit while maintaining sputter shielding functionality.
Solution Approach 2:
The shielding member is positioned specifically between the work pieces and the housing case to provide localized sputter protection. By placing it only where sputter occurs rather than covering the entire housing case, heat transfer path is minimized while maintaining protective function in the critical area.
2Reliability
If the sensor unit is exposed to radiation heat above its heat resistant temperature, then durability is reduced and thermal expansion occurs, but the shielding member made of same material as housing case transfers heat uniformly throughout the structure
Solution Approach 1:
The shielding member acts as a thermal intermediary with lower thermal conductivity, positioned between the heat source (work pieces) and the sensor unit. This intermediary material reduces the rate of heat transfer to the sensor unit, preventing temperature from reaching harmful levels while still allowing the shielding function.
Solution Approach 2:
The system uses different materials for the shielding member and housing case, with the shielding member having lower thermal conductivity. This composite material approach creates a thermal barrier that protects the sensor unit from radiation heat while maintaining structural integrity and sputter shielding capability.
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 minimizes the impact of radiation heat on the sensor unit, ensuring accurate detection and prolonged durability by reducing heat transfer and providing shock absorption.
Implementation Method 1
shielding member adapted to shield radiation heat directed toward the housing case among radiation heat generated while the work pieces are welded together
Implementation Method 2
shielding member made of material with lower thermal conductivity than that of the housing case
Data Source
AI summary
The durability and detection accuracy of a sensor unit may possibly decrease due to radiation heat generated from work pieces 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 work pieces W or the distance to the work pieces 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 work pieces W are welded together. The shielding member 5 is made of a material with lower thermal conductivity than that of the housing case 3.