Welding Torch Retrofit Sensing for Direct Voltage and Current Feedback

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Solution Overview

Problem

Existing welding training systems do not directly measure welding voltage and current within the welding torch, relying on power supplies to estimate these parameters, which can lead to inadequate training for high-quality welds.

Innovation Solution

Incorporating a voltage sensing component and a current sensing component within the welding torch to directly measure and convert welding voltage and current, providing accurate feedback to operators through a computer system, and offering these components as a retrofit kit for existing torches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If voltage sensing component and current sensing component are incorporated within the welding torch to directly measure welding parameters, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvewelding voltage and current measurement accuracyVSAvoidtorch structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The voltage sensing component and current sensing component are nested within the existing welding torch structure. The voltage sensor is integrated into the torch body near the electrode, while the current sensor is incorporated into the cable assembly, allowing both sensing functions to be embedded without requiring a completely new torch design.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The sensing components are merged with the welding torch system, combining measurement functions with the existing welding delivery mechanism. The voltage and current sensors work together with the torch's electrical circuitry to provide integrated real-time monitoring of welding parameters.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If sensing components are integrated into the welding torch, then reliability of welding training is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvewelding training system reliabilityVSAvoidtorch manufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sensing system is segmented into separate modular components - the voltage sensor, current sensor, and control unit - that can be manufactured independently and then assembled into the welding torch. This modular approach allows each component to be optimized for its specific function while simplifying the overall manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensing components are designed to be pre-assembled and pre-tested as separate units before being integrated into the welding torch. This preliminary preparation ensures proper functionality and reduces assembly complexity during final torch manufacturing.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If real-time measurement and feedback of welding parameters is provided, then manufacturing precision of welds is improved, but loss of energy increases

Engineering Contradiction:

Improveweld qualityVSAvoidenergy consumption for sensing and feedback

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The system replaces complex mechanical measurement methods with electronic sensing components that measure voltage and current directly through electrical fields. This substitution reduces mechanical complexity and energy consumption while improving measurement precision and real-time feedback capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

Enables precise measurement and feedback of welding parameters, enhancing the training process by providing operators with real-time data to improve welding techniques and quality.

Implementation Method 1

a voltage sensing component and a current sensing component disposed in a welding torch to directly measure the welding voltage and the welding current

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a voltage sensing component and a current sensing component disposed in a welding torch to directly measure the welding voltage and the welding current

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3127404B1Welding or plasma cutting torch

Publication Date: 2024.03.27 ILLINOIS TOOL WORKS INC

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AI summary

A retrofit module includes at least one of a current sensing component that has a first circuit or a voltage sensing component that has a second circuit. The current sensing component and the voltage sensing component may be disposed in a torch head of a welding or plasma cutting torch. The current sensing component is configured to measure a welding or plasma cutting current of the torch head, and the voltage sensing component is configured to measure a welding or plasma cutting voltage of the torch head.