Welding Torch Sensor Layout for Faster Interpass Temperature Checks
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Solution Overview
Problem
In welding robots, the process of measuring interpass temperature is hindered by the need to move the welding torch away from the workpiece to avoid interference with temperature sensors, leading to increased preparation time and risk of interference with surrounding members.
Innovation Solution
A welding system with a movable temperature sensor attached to the welding torch, where the sensor's measurement axis intersects with the torch's axis in a three-dimensional space, allowing for non-contact measurement and reducing interference risks, coupled with a control device that calculates optimal measurement positions and manages interpass temperature thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is attached to the upper surface of the torch clamp to measure interpass temperature, then the measurement function is achieved, but the welding torch must be moved away from the workpiece to avoid interference, increasing preparation time
Solution Approach 1:
The temperature sensor is positioned on the side surface of the torch clamp rather than the upper surface, changing the spatial arrangement from a two-dimensional top-view configuration to a three-dimensional side-view configuration. This allows the sensor to measure temperature at the measurement point without requiring the torch to be moved away, as the side position avoids interference with the workpiece while maintaining measurement capability
Solution Approach 2:
The temperature sensor is specifically positioned at a location on the side surface that corresponds to the measurement point on the workpiece, creating a localized measurement zone. This precise local positioning ensures accurate temperature measurement while minimizing the space required and avoiding interference with surrounding members
2Measurement precision
If the temperature sensor is attached to the torch clamp, then temperature measurement is enabled, but interference with surrounding members occurs during welding operations
Solution Approach 1:
By positioning the sensor on the side surface rather than the upper surface, the measurement function is achieved in a different spatial dimension that does not conflict with the welding torch's operational space or surrounding members, thereby eliminating interference while maintaining measurement precision
3Measurement precision
If multiple operations are required to position the temperature sensor for measurement, then accurate temperature measurement is achieved, but the complexity of the measurement process increases
Solution Approach 1:
The temperature sensor is integrated directly into the torch clamp structure, merging the measurement function with the existing torch assembly. This eliminates the need for separate positioning operations and reduces measurement process complexity while maintaining accurate temperature measurement capability
Solution Approach 2:
The sensor is positioned at a specific location on the side surface that directly corresponds to the measurement point, creating a localized measurement configuration that requires minimal positioning adjustments and simplifies the overall measurement process
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 solution reduces the time required for temperature measurement and minimizes interference between the welding robot and surrounding members, enhancing operational efficiency by allowing for precise and efficient interpass temperature measurement.
Implementation Method 1
a temperature sensor that is attached to the movable portion and measures an interpass temperature of an object to be welded present on a measurement axis in a noncontact manner
Data Source
AI summary
A welding system includes: a welding robot having a movable portion that can move integrally with a welding torch; a control device that controls movement of the welding robot; and a temperature sensor that is attached to the movable portion and measures an interpass temperature of an object to be welded present on a measurement axis in a noncontact manner. A central axis of the welding torch and the measurement axis of the temperature sensor are in a relation of three-dimensionally intersecting in a space, and a position where the central axis and the measurement axis three-dimensionally intersect is ahead of a tip end of the welding torch on the central axis of the welding torch. The control device controls movement of the welding torch such that the measurement axis is positioned at a measurement position of the temperature calculated in advance.