Wire Marking Reader for Orientation-Independent Welding Consumable Tracking
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Solution Overview
Problem
Existing welding systems face challenges in determining the remaining length of consumables like metal wire without interrupting the operation and accurately setting weld parameters based on consumable properties, often relying on user inspections or manual scanning which can lead to incorrect settings.
Innovation Solution
A reader module with multiple optical sensors radially arranged around the consumable path scans encoded markings on the wire, such as bar codes, to detect consumable type, authenticity, and remaining length, ensuring consistent reading regardless of wire orientation, and communicates this information to the power source for setting appropriate welding parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection of consumable length is performed, then remaining length can be determined, but welding operation must be stopped and productivity decreases
Solution Approach 1:
The system performs preliminary actions by marking the consumable wire during manufacturing with encoded information about length and properties. This allows the reading device to determine remaining length without stopping the welding operation, as the information was prepared in advance on the wire itself.
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated optical reading system. The reading device uses optical sensors to scan and decode markings on the wire, substituting human visual inspection with automated optical detection that operates continuously during welding.
2Loss of information
If user visually inspects consumable markings, then consumable properties can be identified, but settings may be incorrect due to user error
Solution Approach 1:
The reading device provides feedback by automatically detecting and communicating consumable properties to the welding power source. This closed-loop feedback system eliminates manual reading and interpretation errors, as the system directly receives accurate information from the encoded markings and uses it to set appropriate parameters.
Solution Approach 2:
The consumable wire serves itself by containing encoded information about its properties and length. The reading device simply needs to scan this pre-encoded information, and the system automatically determines the correct settings without requiring user knowledge or manual configuration.
3Device complexity
If single optical sensor is used to read wire markings, then device complexity is reduced, but reading accuracy decreases when wire orientation varies
Solution Approach 1:
The reading device divides the detection task among multiple optical sensors positioned at different angular locations. Each sensor monitors a specific angular position, and the system segments the 360-degree wire circumference into multiple detection zones, ensuring that at least one sensor can detect markings regardless of wire rotation.
Solution Approach 2:
The patent adds the angular dimension to the detection system by arranging sensors radially around the wire path. Instead of a single linear sensor, the system uses multiple sensors distributed in an angular dimension, creating a radial array that can detect markings from any rotational position of the wire.
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 automatic and accurate tracking of consumable usage, ensuring proper weld settings and authentic consumable use, reducing the need for manual inspections and preventing operational interruptions.
Implementation Method 1
A reader includes a plurality of optical sensors radially spaced apart from one another. The reader scans for marks on the consumable as the consumable passes through the reader.
Data Source
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Figure 1B
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AI summary
Techniques for automatic reading of marked consumables are disclosed. The techniques involve a reader having a plurality of sensors for receiving a marked consumable and detecting includes markings on the consumable, regardless of the orientation of the consumable to the reader.