Arc welding torch

Abstract

An arc welding torch for robotic applications having sensing capabilities to provide intelligent diagnostics monitoring of the welding process in real time. A plurality of modular sensors are integrated with the torch to provide real-time monitoring of wire speed, arc voltage, gas flow, seam-tracking, welding current temperature and contact tip wear. The torch includes a contact tip wear sensor for sensing the wearing of the tip during the welding process. The shielding gas flow is measured by a gas flow sensor mounted between the main housing and the gooseneck. A seam-tracking sensor is mounted on the outside of the housing to detect the position of the seam to be welded. The speed of the consumable electrode is measured by a wire speed sensor module. To ensure that operating temperatures of components near the arc region are within predetermined ranges for optimum performance of the torch, temperature sensors are mounted on the torch. An arc voltage sensor is located in the housing of the torch to provide a more accurate measurement of the arc voltage near the arc region. Lastly, a current sensor is located between the main housing and the gooseneck to measure the current flow through the torch. All of the above sensors may be operatively connected to a weld controller which analyze the information received from each sensor to maintain an optimum welding process.