Welding Torch Sensor Integration for Direct Voltage and Current Feedback

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Solution Overview

Problem

Existing welding training systems do not directly measure the welding voltage and current conveyed through a conductor within the welding torch, limiting the feedback provided to operators and the quality of training.

Innovation Solution

Incorporating a voltage sensing component and a current sensing component into the welding torch, which measure the welding voltage and current respectively, and convert these signals for feedback to a computer system, allowing for direct measurement and improved training.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If welding training systems do not directly measure voltage and current, then the system complexity is reduced, but the measurement precision and feedback quality deteriorate

Engineering Contradiction:

Improvevoltage and current measurementVSAvoidtorch structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The voltage sensing component and current sensing component are nested within the torch body structure. The voltage sensing component is at least partially disposed in the torch body, and the current sensing component is also integrated within the torch body, allowing measurement functionality to be embedded without significantly increasing external complexity

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The torch body serves multiple functions: it acts as both the structural housing for welding operations and as the container for the sensing components. This multi-functionality reduces the need for separate measurement devices, thereby improving measurement precision while minimizing additional complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of information

If sensing components are integrated into the torch, then the feedback quality improves, but the ease of manufacture deteriorates

Engineering Contradiction:

Improvewelding parameter feedbackVSAvoidtorch assembly

Core Design Contradiction:

Loss of informationVSEase of manufacture

Solution Approach 1:

The sensing system is segmented into distinct functional components: a voltage sensing component with voltage sensing circuitry and a current sensing component with current sensing circuitry. This segmentation allows each component to be manufactured and tested independently before integration, improving ease of manufacture despite the added functionality

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The voltage sensing component and current sensing component act as intermediaries between the welding arc and the control system. These components convert physical welding parameters (voltage and current) into measurable signals that can be transmitted to the control system, preserving information without requiring complex direct measurement systems

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11883910B2Systems and methods for measuring voltage and current within a welding torch

Publication Date: 2024.01.30 ILLINOIS TOOL WORKS INC

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.