US5463201A — Seam-tracking apparatus for a welding system empl…

Claim 1

Independent Claim 288 words

A seam-tracking apparatus for a welding system in which an advancing welding arm directs at least one energy beam toward a tightly jointed seam having a varying curvature that is between at least a pair of abutting workpieces to be welded, said seam-tracking apparatus comprising: an unitary eddy current sensor supported forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; an eddy current signal processor connected to each of said eddy current elements in the array to receive and to process each of said electrical signals, said eddy current signal processor generating position data indicative of the current location of said tightly joined seam in accordance with the processed electrical signals; and a controller connected to said eddy current signal processor, said controller responsive to said position data for aligning said unitary eddy current sensor between said pair of abutting workpieces wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam, and for aligning said welding arm over said tightly joined seam wherein energy beams directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 2

Dependent Claim 288 words

A seam-tracking apparatus for a welding system in which an advancing welding arm directs at least one energy beam toward a tightly jointed seam having a varying curvature that is between at least a pair of abutting workpieces to be welded, said seam-tracking apparatus comprising: an unitary eddy current sensor supported forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; an eddy current signal processor connected to each of said eddy current elements in the array to receive and to process each of said electrical signals, said eddy current signal processor generating position data indicative of the current location of said tightly joined seam in accordance with the processed electrical signals; and a controller connected to said eddy current signal processor, said controller responsive to said position data for aligning said unitary eddy current sensor between said pair of abutting workpieces wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam, and for aligning said welding arm over said tightly joined seam wherein energy beams directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 3

Dependent Claim 51 words

A seam tracking apparatus in accordance with claim 1, wherein each of said eddy current elements comprises at least a pair of sense coils electrically interconnected in a differential mode, wherein the pair of sense coils is interconnected by a connecting segment providing a virtual ground used as a reference potential.

Claim 4

Dependent Claim 38 words

A seam tracking apparatus in accordance with claim 2, wherein at least one of the sense coils produces a positive output voltage as a seam is approached and at least another sense coil produces a negative output voltage.

Claim 5

Dependent Claim 17 words

A seam-tracking apparatus in accordance with claim 1 wherein said array of eddy current elements is flexible.

Claim 6

Dependent Claim 19 words

A seam-tracking apparatus in accordance with claim 4 and further comprising a flexible structure for accommodating said flexible array.

Claim 7

Dependent Claim 35 words

A seam tracking apparatus in accordance with claim 5, further comprising biasing means for conforming said array of eddy current elements against a surface of at least one of said workpieces having a varying curvature.

Claim 8

Dependent Claim 51 words

A seam tracking apparatus in accordance with claim 6, wherein each of said eddy current elements comprises at least a pair of sense coils electrically interconnected in a differential mode, wherein the pair of sense coils is interconnected by a connecting segment providing a virtual ground used as a reference potential.

Claim 9

Dependent Claim 31 words

A seam-tracking apparatus in accordance with claim 7, wherein said at least a pair of sense coils is electrically interconnected and disposed within said flexible structure using a photolithographic fabrication process.

Claim 10

Dependent Claim 21 words

A seam tracking apparatus in accordance with claim 1, wherein the array of spatially correlated eddy current elements is two dimensional.

Claim 11

Dependent Claim 291 words

A welding system in which at least one energy beam is directed from an advancing welding arm toward a tightly joined seam having a varying curvature that is between at least a pair of abutting workpieces to be welded, said welding system comprising: a beam source for producing said energy beam; an unitary eddy current sensor supported forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; an eddy current signal processor connected to each of said eddy current elements in the array to receive and to process each of said electrical signals, said eddy current signal processor generating position data indicative of the current location of said tightly joined seam in accordance with the processed electrical signals; and a controller connected to said eddy current signal processor, said controller responsive to said position data for aligning said unitary eddy current sensor along said workpieces wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam, and for aligning said welding arm over said tightly joined seam wherein energy beams directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 12

Dependent Claim 291 words

A welding system in which at least one energy beam is directed from an advancing welding arm toward a tightly joined seam having a varying curvature that is between at least a pair of abutting workpieces to be welded, said welding system comprising: a beam source for producing said energy beam; an unitary eddy current sensor supported forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; an eddy current signal processor connected to each of said eddy current elements in the array to receive and to process each of said electrical signals, said eddy current signal processor generating position data indicative of the current location of said tightly joined seam in accordance with the processed electrical signals; and a controller connected to said eddy current signal processor, said controller responsive to said position data for aligning said unitary eddy current sensor along said workpieces wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam, and for aligning said welding arm over said tightly joined seam wherein energy beams directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 13

Dependent Claim 50 words

A welding system in accordance with claim 10, wherein each of said eddy current elements comprises at least a pair of sense coils electrically interconnected in a differential mode, wherein the pair of sense coils is interconnected by a connecting segment providing a virtual ground used as a reference potential.

Claim 14

Dependent Claim 37 words

A welding system in accordance with claim 11, wherein at least one of the sense coils produces a positive output voltage as a seam is approached and at least another sense coil produces a negative output voltage.

Claim 15

Dependent Claim 20 words

A welding system in accordance with claim 10, wherein the array of spatially correlated eddy current elements is two dimensional.

Claim 16

Dependent Claim 17 words

A welding system in accordance with claim 10, wherein said array of eddy current elements is flexible.

Claim 17

Dependent Claim 19 words

A welding system in accordance with claim 14 and further comprising a flexible structure for accommodating said flexible array.

Claim 18

Dependent Claim 34 words

A welding system in accordance with claim 15, further comprising biasing means for conforming said array of eddy current elements against a surface of at least one of said workpieces having a varying curvature.

Claim 19

Dependent Claim 50 words

A welding system in accordance with claim 16, wherein each of said eddy current elements comprises at least a pair of sense coils electrically interconnected in a differential mode, wherein the pair of sense coils is interconnected by a connecting segment providing a virtual ground used as a reference potential.

Claim 20

Dependent Claim 31 words

A welding system in accordance with claim 17, wherein said at least a pair of sense coils is electrically interconnected and disposed within said flexible structure using a photolithographic fabrication process.

Claim 21

Dependent Claim 17 words

A welding system in accordance with claim 18 wherein said beam source comprises an electron beam source.

Claim 22

Dependent Claim 17 words

A welding system in accordance with claim 18 wherein said beam source comprises a laser beam source.

Claim 23

Independent Claim 249 words

A method for continuously tracking a tightly joined seam having a varying curvature that is between at least a pair of abutting workpieces to be welded by means of an advancing welding arm in a welding operation, comprising the steps of: operating an unitary eddy current sensor forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; processing each electrical signal produced by each of said eddy current elements in the array to generate position data indicative of the position of said tightly joined seam; aligning, in response to said position data, said unitary eddy current sensor over said tightly joined seam wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam; and aligning said advancing welding arm over said tightly joined seam wherein beams of energy directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 24

Independent Claim 249 words

A method for continuously tracking a tightly joined seam having a varying curvature that is between at least a pair of abutting workpieces to be welded by means of an advancing welding arm in a welding operation, comprising the steps of: operating an unitary eddy current sensor forwardly of said advancing welding arm, said unitary eddy current sensor comprising a plurality of spatially correlated eddy current elements forming an array having successive rows of said eddy current elements, said successive rows positioned wherein each of said eddy current elements in each of the successive rows are spatially staggered a predetermined distance from each other and staggered in a direction perpendicular to the varying curvature of the tightly joined seam, each of said eddy current elements in each of the successive rows producing an electrical signal in response to being positioned adjacent to said tightly joined seam; processing each electrical signal produced by each of said eddy current elements in the array to generate position data indicative of the position of said tightly joined seam; aligning, in response to said position data, said unitary eddy current sensor over said tightly joined seam wherein at least a portion of said eddy current elements in the array is continuously positioned over the varying curvature of said tightly joined seam; and aligning said advancing welding arm over said tightly joined seam wherein beams of energy directed from said welding arm continuously and directly impinge on the varying curvature of said tightly joined seam.

Claim 25

Dependent Claim 48 words

A process according to claim 21, wherein each of said eddy current elements comprises at least a pair of sense coils electrically interconnected in a differential mode, wherein the pair of sense coils is interconnected by a connecting segment providing a virtual ground used as a reference potential.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-10-30	1999-05-01	1999-10-31	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-10-30	2003-05-01	2003-10-31	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-10-30	2007-05-01	2007-10-31	$7700.00	Window Closed / Lapsed

Seam-tracking apparatus for a welding system employing an array of eddy current elements

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