About:
This project was my first major contribution to a real job. It also marks my first task as an engineer. They had an electronics
related problem, and it was up to me to try to solve it. With a little thinking, tinkering, and a little good old fashioned
know-how, I designed and assembled this working sensor attachment.
Background:
For design, manufacturing, simulation, and statistical purposes, the amount of filler-rod/welding-wire deposted onto the hydro
turbines needs to be accurately recorded. In the past, measurements were estimated based upon the number of spools and barrels
used up until completion. Recently, a device called a WireTrak was installed at the feeds of these barrels for keeping track of
the lengths of wire used. The WireTrak is basically a box with an encoder wheel that can determine distances based on the number
of revolutions it completes.
Resolution:
Only total the exiting wire while an electric arc is present.
Purpose:
This modification and add-on to the WireTrak will prevent it from taking extraneous readings during work shifts. After the
modifications have been made and the add-on is in place, the WireTrak will only conduct its recordings while the welder is
welding the work piece.
Additional Pics:
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This is the actuall WireTrak unit. It mounts to the tops of the weld-wire barrels and measures the lengths of wire
consumed with its encoder wheel.
The wire with the red connecter sticking out of its right side is the modification
it had undergone. That connector attaches the WireTrak to the add-on.
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Here is the finnished add-on. The electro magnetic field sensor attaches to this box. When a field is present
(the welder is welding) this box will tell the WireTrak that it's now ok to collect data.
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This is the field sensor. It is actually a gripper with a small cylindrical magnetic pick-up relay inside. It
clamps on to the welding cable and determines when an arc is present by means of mutual induction from the
huge flowing currents.
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The Documentation:
The work and diagrams for this procedure had to be clearly documented and submitted as a proposal before beginning. The scans
here show how I modified the WireTrak and how I built the add-on.
