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Cavitar Welding Camera
Guide for cooling
Contents
1.
Introduction .......................................................................................................................................... 2
2.
Passive cooling ...................................................................................................................................... 2
2.1
Usage of thermally conductive sheets .......................................................................................... 3
2.2
Mounting to machinery ................................................................................................................ 8
2.3
Heat sinks ...................................................................................................................................... 8
3.
Active cooling ...................................................................................................................................... 10
3.1 Installation to camera ....................................................................................................................... 10
3.2
Thermal insulation from the environment ................................................................................. 11
3.3
Condensation .............................................................................................................................. 14
3.4 About the tests .................................................................................................................................. 16
3.5
Air cooling ................................................................................................................................... 18
3.5.1 Pressurized air ............................................................................................................................ 18
3.5.2 Vortex pipe ................................................................................................................................. 18
3.6
Liquid cooling .............................................................................................................................. 19
3.6.1 Requirements and recommendations ....................................................................................... 19
3.6.2 Radiator solution ........................................................................................................................ 19
3.6.3 Recirculating chiller .................................................................................................................... 20
3.6.4
Other possibilities ............................................................................................................... 21
3.7 Liquid cooling with pressurized air insulation................................................................................... 21
4 Summary .................................................................................................................................................. 22
Cavitar Welding Camera, C300 and C400 series Guide for cooling, Revision 1.1.1 © 2022 Cavitar Ltd. All rights reserved. All unauthorized copying strictly prohibited. Cavitar® is a registered trademark of Cavitar Ltd.
Страница 1: ... About the tests 16 3 5 Air cooling 18 3 5 1 Pressurized air 18 3 5 2 Vortex pipe 18 3 6 Liquid cooling 19 3 6 1 Requirements and recommendations 19 3 6 2 Radiator solution 19 3 6 3 Recirculating chiller 20 3 6 4 Other possibilities 21 3 7 Liquid cooling with pressurized air insulation 21 4 Summary 22 Cavitar Welding Camera C300 and C400 series Guide for cooling Revision 1 1 1 2022 Cavitar Ltd All...
Страница 2: ...d arm having a metallic clamp Cavitar Welding Cameras have built in safety measures for warning about increasing camera temperature With C300 series the camera temperature is shown in Cavitar Capture software and warnings will be displayed on the screen see the C300 operation manual for more details With C400 series warnings are generated by a separate temperature warning unit see the C400 operati...
Страница 3: ...clean sufficiently large to cover the entire interface area and unused Ensure the surfaces to be joined are properly cleaned o Dirt in the interface can prevent proper thermal contact between the surfaces Always ensure that possible protective foils are removed before use o Protective foils typically have very poor thermal conductivity and if they are not removed heat transfer from camera to heat ...
Страница 4: ...Page 4 of 22 Fig 2 2 Ensure the camera sides are clean Fig 2 3 Remove the protective foil from the thermally conductive sheet if applicable ...
Страница 5: ...ig 2 4 Place the thermally conductive sheet over the camera and mark the locations of the threads Fig 2 5 Place the heat sink over the thermally conductive sheet and mount the heat sink with three screws DIN912 M3x8 ...
Страница 6: ...Page 6 of 22 Fig 2 6 Heat sink mounted to the camera Fig 2 7 Repeat the procedure for the other side ...
Страница 7: ...Page 7 of 22 Fig 2 8 Remove excess sheet if applicable Fig 2 9 Heat sinks successfully mounted ...
Страница 8: ...ld be sufficiently large preferably at least similar contact area as between the mount and the camera It is possible to reduce the effect of external heat loads by adding thermal insulation around the camera and the mount e g thermally insulating sleeve 2 3 Heat sinks Cavitar offers dedicated heat sinks see Section 2 2 for mounting details that can be applied if passive cooling is sufficient but t...
Страница 9: ...Page 9 of 22 Fig 2 10 Stabilized C300 camera temperature with heat sinks with and without air flow Fig 2 11 Mechanical dimensions of the heat sink for C300 ...
Страница 10: ...cooling Section 3 6 is even more efficient and for the most extreme conditions air and liquid cooling can be combined Section 3 7 3 1 Installation to camera Figure 3 1 shows typical active cooling components 2x cooling connector 2x cooling hose and 2x hose clamp before and after installation to the camera First the cooling connectors are connected to the threads of the camera unit ensure O rings a...
Страница 11: ...id fiber blanket with aluminium coating o Reflects at least 90 of radiant heat energy o Continuous temperature up to 340 C o Short term temperature up to 540 C o Momentary 1 min temperature up to 1650 C Before applying protective sleeves the proper cooling of electrical cables must be arranged This can be done by twisting the cooling hoses around the electrical cables as shown in Fig 3 2 Fig 3 2 T...
Страница 12: ...perature The most efficient insulation arrangement is the following Cooling hoses twisted around electrical cables Aluminium foil wrapped around camera housing as well as hoses and cables behind the camera Cables and camera insulated with several thermally insulating protective sleeves with outermost sleeve being air tight Low pressure air blown through the system in this case air must be able to ...
Страница 13: ...ulation arrangements may be sufficient As an example in moderate ambient temperatures it may not be necessary to insulate the camera housing Therefore if needed space can be saved by protecting only the cables with protective sleeves This is shown in Figs 3 6 3 8 please note that the steps shown in Figs 3 2 and 3 3 have been carried out beforehand In this example effectively three layers of Thermo...
Страница 14: ...Ambient C 290 290 Camera body top side C 80 52 Camera body bottom side C 64 43 Cables C 76 67 Camera C 47 39 Cooling liquid C 25 25 3 3Condensation Condensation occurs whenever there is humidity in air and the temperature of an object falls below the dew point Condensation must be avoided since it can damage the welding camera Condensation can be prevented by keeping the cooling medium air or liqu...
Страница 15: ...e temperature of the coolant must be above 27 C in order to avoid condensation As can be seen from Fig 3 9 it is always safe from the condensation point of view to use coolant temperature at or above ambient temperature In this respect the radiator solution see Section 3 6 2 is an easy way to avoid condensation issues provided that the radiator is located appropriately ...
Страница 16: ...camera was not insulated see Figs 3 2 3 3 and 3 6 3 8 except in the recirculating chiller tests which were done also with the camera insulated see Fig 3 5 In the case of combined air and liquid cooling Section 3 7 the insulation consisted of one pyrojacket no thermosleeves applied and the interface between camera housing and pyrojacket was not sealed see Fig 3 11 to let the air flow through the sy...
Страница 17: ...constant cooling liquid temperature 25 C was applied and both the cables and the camera were insulated Fig 3 12 Evolution of temperatures recirculating chiller cables and camera insulated It is important to note that the results are indicative and valid only for the described test setup The length of insulation was less than 1 m and there was no heat load from arc process ...
Страница 18: ... exhaust air can be forced to travel back inside the protective sleeve by sealing the camera end of the insulation see Figs 3 5 or 3 8 Pressurized air should be sufficiently pure no water or oil and the pressure shouldn t be excessive Ideal temperature for the pressurized air is 25 30 C to avoid condensation and enable efficient cooling Fig 3 13 shows the maximum ambient temperature camera tempera...
Страница 19: ... system must be properly flushed and cleaned before adding suitable inhibited glycol and pure water mixture as well as when the mixture needs to be changed Prevent any contamination of the cooling liquid and cooling circuitry Cooling solution with temperature and flow rate monitoring and alarm feature is recommended Regular maintenance intervals are needed to ensure proper operation e g checking t...
Страница 20: ... Another important aspect with the chiller is to ensure that the chiller can be used together with the welding camera since the cooling channels inside the camera are made of aluminium corrosion must be prevented The results from the tests with recirculating chiller were presented in Table 3 1 reproduced below Table 3 1 Results with recirculating chiller without with camera insulation Temperature ...
Страница 21: ...ent separately In this cooling method the camera and the cables are thermally insulated from the environment and the camera end of the insulation is not fully sealed Liquid cooling is connected to the cooling connectors of the welding camera and pressurized air is blown through the insulation in such a way that the air escapes the insulation from the camera end Liquid cooling keeps the camera cool...
Страница 22: ...ility ranges of different cooling methods under the test conditions described in earlier chapters of this guide no heat load from the arc It is important to keep in mind that the results are indicative and the suitability of the selected cooling solution must be confirmed separately for each application and environment Table 4 1 Applicability ranges of different cooling methods under the applied t...
