• Journal of Sensor Science and Technology
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• v.25 no.3
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• pp.208-212
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• 2016

In this work, a loop sensor for Arc-Flash detections has been developed in order to trip a circuit breaker within 2.5 ms after an Arc-Flash event. For an efficient capturing of the flash light, plastic optical fibers, where light attenuations are larger than those in silica-based ones, with different diameters and surface conditions were utilized. The performance was comparatively analyzed with those of a point sensor and a commercialized product. The point sensor module was designed for hemisphere-like capturings of Arc-Flashes larger than 3 kA at 2 meters from the sensor. On the other hand, the loop sensor allowed 360-degree-detections around the fiber axis and the measurement range was dependent on the length of the fiber connected to the sensor module. The trip-level-dependent brightness measurement results showed that the fabricated point sensor and loop sensor satisfied a brightness condition, 10~40 klux, and the responses of the system to Arc-Flashes were completed within 2.5 ms.

• Journal of Welding and Joining
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• v.13 no.1
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• pp.115-126
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• 1995

Vision sensors using the optical triangulation have been widely used for automatic welding systems in various ways, but their reliability is seriously affected by presence of the arc noise. The reliability of vision sensors was analyzed with variation of the arc noise by considering the reflectance of the base metal. first, the properties of the base metal's reflection were modelled by using the Bidirectional Reflectance-Distribution Function(BRDF), and then the variation of the reflected arc intensity was formulated for various configurations of the torch, base metal, and sensor. The experimental data of the gray level of the reflected arc light were obtained for two materials, mild steel and stainless steel. It was found that the results calculated from the proposed model were in good agreement with the experimental data.

• Journal of Welding and Joining
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• v.14 no.5
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• pp.113-121
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• 1996

The arc sensor has been most widely used for weld seam tracking through welding current or voltage variation. In this work, the relation between the arc light intensity and welding condition is investigated using heat balance in the Plasma for its possible application to seam tracking in the GMAW process. The arc light intensity is derived to be the function of the arc length and welding current Experiments are carried out to verify the proposed heat balance model. Performances of least square and integration methods to process the signals for seam tracking are compared experimentally. Predicted arc light intensity shows reasonably good agreement with experimental results. The weld seam is successfully tracked through the arc light intensity. The least square and integration methods demonstrate almost same performance of seam tracking with $CO_2$gas shielding.

• Proceedings of the Korean Institute of Electrical and Electronic Material Engineers Conference
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• 2010.06a
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• pp.221-221
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• 2010

수배전반 내부에서 Arc 사고 발생시 동반되는 광신호를 검출할 수 있는 광센서를 개발하였다. 개발된 광센서는 특정 부위에 설치되어 해당 위치에서 발생하는 광신호를 검출하는 Point Sensor와 넓은 범위를 감시할 수 있는 Loop Sensor의 두 가지 형태로 구성되어 있다. 두 가지 모두 광섬유를 통하여 계전기 등에 부착되며, 일반 통신용 광섬유보다 큰 core를 갖는 특수 광섬유가 사용되었다. Point Sensor는 광섬유 끝단에 부착된 Cap에 의해 광신호가 검출되고, Loop Sensor는 광섬유 자체가 Sensor로 사용되어 광신호의 검출 및 전승을 수행한다. Point Sensor에 부착되는 Cap은 보다 넓은 범위 감시하고, 광신호 발생 위치에 따른 편차를 줄일 수 있는 형태로 설계되었다.

• International Journal of Korean Welding Society
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• v.2 no.2
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• pp.51-56
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• 2002

The weld seam tracking system for arc welding process uses various kinds of sensors such as arc sensor, vision sensor, laser displacement sensor and so on. Among the variety of sensors available, electro-magnetic sensor is one of the most useful methods especially in sheet metal butt-joint arc welding, primarily because it is hardly affected by the intense arc light and fume generated during the welding process, and also by the surface condition of weldments. In this study, a dual-electromagnetic sensor, which utilizes the induced current variation in the sensing coil due to the eddy current variation of the metal near the sensor, was developed for arc welding of sheet metal I-butt joints. The dual-electromagnetic sensor thus detects the offset displacement of weld line from the center of sensor head even though there's no clearance in the joint. A set of design variables of the sensor was determined far the maximum sensing capability through the repeated experiments. Seam tracking is performed by correcting the position of sensor to the amount of offset displacement every sampling period. From the experimental results, the developed sensor showed the excellent capability of weld seam detection when the sensor to workpiece distance is near less than 5 ㎜, and it was revealed that the system has excellent seam tracking ability for the I-butt joint of sheet metal.

• Journal of Welding and Joining
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• v.18 no.4
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• pp.70-75
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• 2000

The weld seam tracking system for arc welding process uses various kinds of sensors such as arc sensor, vision sensor, laser displacement and so on. Among the variety of sensors available, electro-magnetic sensor is one of the most useful methods especially in sheet metal butt-joint arc welding, primarily because it is hardly affected by the intense arc light and fume generated during the welding process, and also by the surface condition of weldments. In this study, a dual-electromagnetic sensor, which utilizes the induced current variation in the sensing coil due to the eddy current variation of the metal near the sensor, was developed for arc welding of sheet metal butt-joints. The dual-electromagnetic sensor thus detects the offset displacement of weld line from the center of sensor head even though there's no clearance in the joint. A set of design variables of the sensor were determined for the maximum sensing capability through the repeated experiments. Seam tracking is performed by correcting the position of sensor to the amount of offset displacement every sampling period. From the experimental results, the developed sensor showed the excellent capability of weld seam detection when the sensor to workpiece distance is near less than 5 mm, and it was revealed that the system has excellent seam tracking ability for the butt-joint of sheet metal.

• Journal of Welding and Joining
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• v.18 no.4
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• pp.82-86
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• 2000

Gas metal arc welding(GMAW) is regarded as one of the best candidate for welding automation in industrial joining application. It is important to monitor the weld quality for the high performance weld automation. In GMAW, weld quality is closely related to arc stability especially. In this paper, arc light signal is measured and spectrum analyzed to the detect the variation of the weld quality. The FFT of the signal showed that the amplitude variance of FFT power spectrum was very large in poor weld process such as the decrease of weld bead width and height. The results show that it is possible to detect the weld defect position in weld process.

• Journal of Welding and Joining
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• v.13 no.4
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• pp.65-74
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• 1995

The weld seam tracking sensor is indispensable to improve the flexibility of automatic arc welding systems. Among the position sensing methods available, a laser displacement sensor is one of the most prevailing methods. In this study, a laser displacement sensor was examined on detecting the weld seam of lap joints in sheet metal arc welding. The output signal of the laser displacement sensor may ontain severe fluctuation from the effect of arc light, spatters, fume, etc. So a variety of signal processing methods was applied to smooth the output signal of the sensor. And then the weld joint was determined by using the central difference method. It was revealed that the quadratic mean method plays an important role in detecting the weld seam during welding especially.

• Journal of Welding and Joining
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• v.8 no.2
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• pp.58-69
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• 1990

In conventional arc welding, position error of the weld torch with respect to the weld seam and variation of groove dimension are induced by inaccurate fitup and fixturing. In this study, a vision system has been developed to recognize and compensate the position error and dimensional inaccuracy. The system uses a structured laser light illuminated on the weld groove and perceived by a C.C.D camera. A new algorithm to detect the edge of the reflected laser light is introduced for real time processing. The developed system was applied to arbitarary weld paths with various types of joint in arc welding process. The experimental results show that the proposed system can detect the weld groove parameters within good accuracy and yield good tracking performance.

• Journal of Sensor Science and Technology
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• v.29 no.1
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• pp.40-44
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• 2020

An integrated multifunctional sensor, capable of raising an early electric-fire warning, was fabricated. An arc-light, temperature, and humidity sensor was fabricated on a flexible substrate using a printed thin film of indium tin oxide. A polyethylene terephthalate (PET) substrate was used as the flexible substrate. The sensor was fabricated on a PET substrate, and its operating characteristics were tested. The operating performances of the sensor when serving as an arc-light, a temperature, and a humidity sensor were estimated to be 0.6247 Ω/W, 80.6 Ω/K, and -4.08 Ω/RH, respectively. The feasibility of the proposed fire sensor was demonstrated; it costs low and offers multiple functionalities.