Cavitar C300 Series Manual

Welding camera guide for cooling

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Operating manual (43 pages)

Operating manual (43 pages)

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Cavitar Welding Camera

Contents

Introduction .......................................................................................................................................... 2

Passive cooling ...................................................................................................................................... 2

2.1

Usage of thermally conductive sheets .......................................................................................... 3

2.2

Mounting to machinery ................................................................................................................ 8

2.3

Heat sinks ...................................................................................................................................... 8

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

Cavitar® is a registered trademark of Cavitar Ltd.

Guide for cooling

Page 1 of 22

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Page 1: Table Of Contents
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.
Page 2: Introduction
All tests have been made with Cavitar Welding Camera C300, but the results and conclusions apply also to Cavitar Welding Camera C400 series. All results are indicative.
Page 3: Usage Of Thermally Conductive Sheets
2.1 Usage of thermally conductive sheets High thermal conductivity sheets should be applied between the camera side(s) and the mounting and/or heat sink(s) in order to maximize heat conductivity. Cavitar offers dedicated thermally conductive sheets and heats sinks for passive cooling as optional accessories.
Page 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).
Page 5 Page 5 of 22 Fig. 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).
Page 6 Page 6 of 22 Fig. 2.6. Heat sink mounted to the camera. Fig. 2.7. Repeat the procedure for the other side.
Page 7 Page 7 of 22 Fig. 2.8. Remove excess sheet, if applicable. Fig. 2.9. Heat sinks successfully mounted.
Page 8: Mounting To Machinery
(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 there is no suitable mounting location in the welding machinery.
Page 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.
Page 10: Active Cooling
Page 10 of 22 3. Active cooling Active cooling is the most efficient solution for challenging conditions (elevated ambient temperature, large heat load from the welding process). The most common means of active cooling include air cooling and liquid cooling. Since active cooling is typically used in challenging environments, it is crucial to ensure continuous and sufficient flow of the coolant to the camera.
Page 11: Thermal Insulation From The Environment
Page 11 of 22 3.2 Thermal insulation from the environment In high temperature environment the efficiency of cooling can be greatly improved by appropriate thermal insulation of the camera and cables from the environment. This is especially important for the cables which are not cooled as efficiently as the camera body.
Page 12 Page 12 of 22 Fig. 3.3. Aluminium foil wrapped around camera housing, cables and hoses. Fig 3.4 shows the effect of the aluminium foil. In this test radiator cooling (see Section 3.6.2 for more details) without camera insulation (but with cables insulated) was applied. Fig.
Page 13 Page 13 of 22 If low-pressure air is not applied, it is important to seal the interface between the camera housing and the outermost protective sleeve (e.g. with Kapton tape) in order to prevent hot ambient air from entering the insulation.
Page 14: Condensation
Page 14 of 22 Fig. 3.7. Thermosleeve B wrapped around the cables and hoses (effectively two additional layers). Fig. 3.8. Pyrojacket pulled over the cables and hoses and sealed to camera housing with Kapton tape. Table 3.1 shows the effect of insulating the camera in addition to the cables. In this test recirculating chiller cooling (see Section 3.6.3 for more details) was applied.
Page 15 Page 15 of 22 Fig. 3.9. Dependence of dew point on ambient temperature and relative humidity. As an example, if the ambient temperature is 30 °C and relative humidity is 80 %, the 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.
Page 16: About The Tests
Page 16 of 22 3.4 About the tests The tests were carried out by putting the camera and cables inside an oven and by logging temperature values from different locations (Fig. 3.10). Also the ambient temperature inside the oven was measured. Body top measurement point Cables Temperature measurement point Body bottom measurement point...
Page 17 Page 17 of 22 An example measurement is shown in Fig. 3.12, where the evolution of different temperatures as a function of time can be seen. In this test recirculating chiller (constant cooling liquid temperature 25 °C) was applied and both the cables and the camera were insulated. Fig.
Page 18: Air Cooling
Page 18 of 22 3.5 Air cooling 3.5.1 Pressurized air Pressurized air can be applied simply by connecting the incoming air hose to either cooling connector of the welding camera. The air will come out from the second cooling connector of the camera. This air can be guided to desired location with a second hose (can also be utilized in air knife).
Page 19: Liquid Cooling
3.6.2 Radiator solution Cavitar has made extensive empirical tests with active liquid cooling utilizing a radiator with fans and a water pump. The cooling liquid is maintained in a temperature close to the ambient temperature at the location of the radiator. Cavitar offers radiator cooling solution that is compatible with the aluminium body of the welding camera.
Page 20: Recirculating Chiller
Page 20 of 22 Fig. 3.13. Camera temperature as a function of ambient temperature (radiator solution). 3.6.3 Recirculating chiller Recirculating chiller maintains the cooling liquid at the set temperature and is the most precise means of liquid cooling (provided that the chiller is sufficiently powerful). The cost of the chiller is typically higher than the cost of the radiator solution.
Page 21: Other Possibilities
Page 21 of 22 3.6.4 Other possibilities In some cases the welding machine may already have liquid cooling and it can be very straightforward to connect the welding camera to the same cooling circuitry. This method of cooling can be applied if the following conditions can be met: •...
Page 22: Summary
Page 22 of 22 4 Summary Different methods of cooling for Cavitar Welding Camera C300 have been discussed and empirical results from different situations have been presented. Table 4.1 below summarizes the applicability ranges of different cooling methods under the test conditions described in earlier chapters of this guide (no heat load from the arc).

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