Welding Wire Remaining Detection Using Inductance-to-Frequency Sensing
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Solution Overview
Problem
In laser composite welding, the remaining amount of welding wire cannot be accurately detected, leading to frequent unnecessary changes and waste due to human judgment errors, and existing detection methods are cumbersome or costly.
Innovation Solution
A non-contact detection system using a detection coil and circuit to convert inductance into a frequency signal, combined with an adaptive algorithm and LED display for real-time monitoring and warning, ensuring accurate detection and visual feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact detection device is used to detect welding wire remaining amount, then detection can be performed, but service life is short and wire change is inconvenient
Solution Approach 1:
The patent replaces the mechanical contact detection device with an electromagnetic field-based detection system. The detection coil generates a magnetic field that interacts with the welding wire without physical contact, converting the mechanical wear problem into a non-contact electromagnetic measurement system that eliminates wear and extends service life.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the detection system and the welding wire. The detection coil uses the magnetic field to sense the wire's presence and remaining amount without direct contact, allowing the wire to pass through freely while still enabling accurate detection.
2Measurement precision
If weighing device is used to detect welding wire remaining amount, then detection accuracy can be improved, but device design and mounting becomes overly complex
Solution Approach 1:
The patent replaces the complex mechanical weighing device with a simple electromagnetic detection coil system. The coil generates a magnetic field that naturally interacts with the ferromagnetic welding wire, providing detection functionality without requiring complex mechanical structures, sensors, or mounting arrangements.
Solution Approach 2:
The patent changes the detection parameter from weight measurement to magnetic field interaction. By using the magnetic properties of the welding wire instead of its weight, the system achieves detection functionality with a much simpler device structure and easier mounting process.
3Measurement precision
If wire feeding software algorithm is used to calculate remaining amount, then calculation can be performed, but accuracy is insufficient
Solution Approach 1:
The patent replaces the software algorithm-based calculation method with a direct electromagnetic detection method. Instead of estimating remaining amount through software algorithms that track wire consumption, the system directly measures the magnetic field interaction between the detection coil and the remaining wire, providing accurate real-time detection without complex calculations.
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
Accurate, reliable, and cost-effective detection of welding wire remaining amount, reducing waste and improving production efficiency by preventing unnecessary wire changes.
Implementation Method 1
the detection circuit is configured to convert an equivalent inductance of the detection coil into a frequency signal in real time
Implementation Method 2
the detection coil is located inside a magnetic field generated by a detected welding wire
Data Source
AI summary
There is provided a welding wire remaining amount detection and warning system which relates to the welding field. The present disclosure aims to solve the problem of inability to detect the welding wire remaining amount in the laser composite welding makeup device. In the present disclosure, in the welding wire remaining amount detection process, based on electromagnetic induction principle, the equivalent inductance of the coil decreases along with decrease of the welding wire. The change of the equivalent inductance of the coil is converted by the LC oscillator circuit into a directly-collectable frequency change signal. By detecting the value of the current frequency, the current welding wire remaining amount can be determined.