Wireless Sensor Data Routing for Harsh Welding Environments
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Solution Overview
Problem
Welding equipment in harsh environments faces challenges with long cable extensions and unreliable wireless communication due to noise and security concerns, particularly in remote locations like shipbuilding where multiple welding systems operate in close proximity.
Innovation Solution
A wireless communication network system that includes a master node device with communication circuitry for both short-range and long-range wireless links, enabling secure communication between welding equipment and power supply units, while managing sensor data and providing capabilities lists, and allowing seamless operation of multiple local wireless networks without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If long cables are extended to remote welding locations, then power supply is achieved, but cable clutter and operational complexity increase
Solution Approach 1:
The patent replaces the mechanical cable-based power and communication system with a wireless communication system. The master node device establishes wireless communication links with welding equipment at remote locations, eliminating the need for physical cable extensions while maintaining power supply coordination and data communication capabilities.
Solution Approach 2:
The master node device acts as an intermediary between the welding power supply unit and remote welding equipment. It receives sensor data from welding equipment and routes it to final destinations, while also providing capabilities information back to sensors, thereby mediating communication without requiring direct cable connections.
2Device complexity
If wireless communication is used in harsh welding environments, then cable clutter is reduced, but communication reliability deteriorates due to noise
Solution Approach 1:
The system implements feedback mechanisms where the master node device receives sensor data from welding equipment and provides capabilities information back to sensors. This bidirectional communication allows for error detection, acknowledgment of data receipt, and adaptive adjustment to maintain reliable communication in noisy industrial environments.
Solution Approach 2:
The master node device serves as an intermediary that manages wireless communication between welding equipment and the welding power supply unit. It handles data routing, sensor capabilities management, and communication coordination to ensure reliable operation despite environmental noise.
3Productivity
If multiple welding systems operate in close proximity, then productivity increases, but wireless network interference increases
Solution Approach 1:
The patent segments the wireless communication network into multiple independent master node devices, each managing its own local wireless network. This segmentation allows multiple welding systems to operate in close proximity without interference, as each master node handles its own sensors and welding equipment independently.
Solution Approach 2:
Each master node device creates a localized wireless network with specific capabilities and parameters optimized for its local environment. The system provides local quality by allowing each network segment to operate independently with its own configuration, reducing interference between multiple welding systems.
Data Source
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AI summary
In certain embodiments, a system includes a master node device. The master node device includes communication circuitry configured to facilitate communication with a welding power supply unit via a long-range communication link, and to facilitate wireless communication with one or more welding-related devices via a short-range wireless communication network. The master node device also includes control circuitry configured to receive sensor data from one or more sensors within a physical vicinity of the short-range wireless communication network, and to route the sensor data to final destinations for the one or more sensors.