Low weight and flexible single cable for carbon dioxide welding machine

Abstract

The present invention relates to a lightweight and flexible single cable for a carbon dioxide gas welding machine, and more specifically, to a lightweight and flexible single cable for a carbon dioxide gas welding machine in which the thickness of the control wire and conductive wire is reduced to lighten the overall weight and improve strength, suppress heat generation caused by resistance, and an electromagnetic shielding means using fabric, non-woven fabric, or paper installed on the inner side of the outer sheath is attached to the outer sheath to prevent the deterioration of the flexible function when the outer sheath is folded. The present invention relates to a method for manufacturing a single cable for a carbon dioxide gas welding machine comprising a rubber outer layer, a gas supply pipe, a power supply power line, a control wire having an operation control function, and an electromagnetic shielding means, wherein the power line is formed by bundling 66 strands of small wire diameters having a diameter of 0.18 mm into three bundles, and then twisting the three bundles into one to form a power line, which is arranged at regular intervals in the circumferential direction to reduce the overall weight and reduce the air gap between the small wire diameters, and thereby due to the said air gap Its characteristic feature is that it reduces the generation of high-temperature heat due to resistance.

Description

Technology Field

[0001] The present invention relates to a lightweight and flexible single cable for a carbon dioxide gas welding machine, and more specifically, to a lightweight and flexible single cable for a carbon dioxide gas welding machine in which the thickness of the control line and power line is reduced so that the overall weight is light and the strength is improved, and the gap formed by the contact between the wire diameters is made small to suppress heat generated by resistance, and an electromagnetic shielding means installed on the inner side of the rubber outer layer is attached to the rubber outer layer to prevent the flexible function from being degraded when the rubber outer layer is bent. Background Technology

[0003] Generally, welding refers to a metallurgical joining technique that involves applying heat or pressure to induce atomic bonding between two solid materials of the same or different types, and various methods such as arc welding, resistance welding, and laser welding are utilized.

[0004] Arc welding is a method that utilizes the heat generated by an arc discharge. It is a technique that uses the heat produced by generating an arc between the base material to be welded and the welding torch to melt the surfaces of the base material and the weldment, and then melts the metal from the welding torch to join them together. Arc welding is classified into inert gas arc welding and CO2 gas arc welding.

[0005] At this time, CO2 gas arc welding is a shielded arc welding technology that uses CO2 gas or a mixed gas mainly consisting of CO2 gas as a shield gas. Since welding is performed by the action of electricity and carbon dioxide as the welding wire is supplied, it is a welding machine that prevents oxidation or nitriding by preventing contact with the atmosphere by preventing spotting from occurring in the molten metal formed in the weld area during the welding process.

[0006] As shown in FIG. 1, this CO2 gas welding machine is generally configured such that a control box (4) that matches the constant torque characteristics and constant speed characteristics of the feed motor of the auxiliary feed device (2) and the feed motor of the main feed device (3) is connected to a power supply unit (1) that supplies welding voltage via a control line (5), and the main feed device (3) is connected to the metal connector, so that welding is performed while the auxiliary feed device (2) supplies CO2 gas from the CO2 gas tank (6) and a control signal to the torch (8) through the torch cable (7), and the feed motor of the auxiliary feed device (2) and the main feed device (3) are connected to the power supply unit (1) via a single cable (9).

[0007] Meanwhile, the structure of the conventional single cable (9) above is composed of a rubber outer layer (71), a gas supply pipe (72), a power supply line (74), a control line (73) having an operation control function, and an electromagnetic shielding member (75) made of non-woven fabric, as shown in the attached drawing Fig. 2.

[0008] However, in this structure, the power supply power line (74) and the control line (73) are intermingled and inserted, the power supply power line (74) is made of copper material and is formed by twisting 94 strands of wire diameter 0.26 mm into 12 bundles and arranging them at regular intervals, and the control line (73) is made of copper material and is formed by twisting 65 strands of wire diameter 0.16 mm into 2 first control lines with a cross-sectional area of ​​1.25 mm² and 65 strands of wire diameter 0.16 mm into 7 second control lines with a cross-sectional area of ​​0.75 mm² arranged at regular intervals.

[0009] At this time, the cable length Conventional single cables are manufactured to weigh 50 kg based on a length of 50 m. As such, the overall weight of the cable is heavy, making it difficult for workers to handle the welding cable as the length increases. Furthermore, in conventional single cables, gaps are formed between the wire diameters, and resistance is generated by these gaps, resulting in the generation of high-temperature heat. The temperatures corresponding to the parts where high temperatures are generated are shown in Table 1.

[0010]

[0011] CH001: The part where the welding machine body and the single cable connect.

[0012] CH002 : Part 1M away from CH001

[0013] CH003 : Part 4M away from CH001

[0014] CH003 : Part 49M away from CH001

[0015] CH004 : Part 25M away from CH001

[0016] CH006 : Welder body

[0017] As shown in Table 1 above, it can be seen that the temperature increases over time, and it can be seen that when the temperature rises due to the resistance, the control line heats up, and the error rate of the control signal increases. In addition, there is a problem in that the power supplied becomes unstable due to the rise in temperature of the power line, causing the weld bead to form irregularly, which leads to a decrease in product quality due to defects in the weld surface.

[0018] Meanwhile, as shown in the attached drawing Fig. 3, when welding a curved section, the single cable must be bent as the electromagnetic shielding means is attached to the outer sheath. However, there is a problem in that the shielding means is attached to the inner side of the outer sheath, which is made of rubber material, thereby reducing the flexible function. Another problem is that the control wire is cut due to fatigue load, which is a major issue that makes the welding machine itself unusable. Prior art literature

[0020] Republic of Korea Utility Model Registration No. 0334121 Republic of Korea Utility Model Registration No. 308495 Republic of Korea Patent Registration No. 1568005 The problem to be solved

[0021] The objective of the present invention is to take into account these conventional problems.

[0022] First, as the thickness of the stranded wires used for conductive and control wires decreases, the gap between the stranded wires during the formation of the conductive and control wires becomes smaller, resulting in a lower resistance value. Consequently, the amount of heat generated due to resistance is reduced, which lowers the heating temperature and thus reduces the error rate, thereby improving welding quality.

[0023] Second, the invention provides a lightweight and flexible single cable for a carbon dioxide gas welding machine that includes an elastic reinforcing wire made of synthetic resin to improve tensile strength and elasticity, and reduces the thickness of the stranded wire used in the conductive wire and control wire to reduce the overall weight, thereby making it easy to move and handle, and has the effect of reducing worker fatigue due to the weight of the single cable. means of solving the problem

[0025] The objective of the present invention, devised in consideration of the aforementioned conventional problems, is achieved by a method for manufacturing a single cable for a carbon dioxide gas welding machine comprising a rubber outer layer, a gas supply pipe, a power supply line, a control line having an operation control function, and an electromagnetic shielding means, wherein the power line is formed by bundling 66 strands of wire diameter 0.18 mm into three bundles, then twisting the three bundles into one, and arranging 11 of them at regular intervals to reduce the total weight and reduce the gap between the wire diameters, thereby reducing the generation of high-temperature heat due to resistance caused by the gaps.

[0026] The method for manufacturing a single cable according to the present invention comprises a single cable for a carbon dioxide gas welding machine, comprising a rubber outer layer, a gas supply pipe, a power line for power supply, a control line having an operation control function, and an electromagnetic shielding means, wherein the power line is formed by bundling 66 strands of wire diameter 0.18 mm into three bundles, then twisting the three bundles into one and arranging them at regular intervals to reduce the total weight and reduce the formation of gaps between the wire diameters, thereby reducing the generation of high-temperature heat caused by said gaps, and the control line is formed by bundling 65 strands of stranded wire 0.16 mm in diameter to form a single line with a nominal cross-sectional area of ​​1.25 mm², comprising: a first control line; This is achieved by a lightweight and flexible single cable for a carbon dioxide gas welding machine, characterized by comprising a second control wire comprising 26 strands of plastically twisted wire with a diameter of 0.16 mm, which are bundled to form a single wire with a nominal cross-sectional area of ​​0.5 mm², and an elastic reinforcing wire made of a synthetic material with a diameter of 400 denier that increases elasticity and elongation, wherein the electromagnetic shielding means comprises a coating layer that prevents adhesion to the outer sheath and a base member made of any one of non-woven fabric, woven fabric, or spandex on which the coating layer is formed.

[0027] Here, the above coating layer is achieved by a single cable for a low-weight and flexible carbon dioxide gas welding machine, characterized in that it is one of silicone, latex, or rubber.

[0028] Here, the above second control line is achieved by a single cable for a low-weight and flexible carbon dioxide gas welding machine characterized by being formed by twisting 20 strands of plastically twisted wires with a diameter of 0.18 mm to form a single wire with a nominal cross-sectional area of ​​0.5 mm² and then adding an elastic reinforcing yarn made of a synthetic resin material that increases elasticity and elongation. Effects of the invention

[0030] The present invention is a useful invention that improves welding quality by reducing the error rate, as the wire diameter used in the conductive wire and control wire becomes thinner, thereby reducing the gap between wire diameters when forming the conductive wire and control wire, which in turn reduces the amount of heat generated due to resistance and lowers the heat generation temperature. Additionally, by including an elastic reinforcing wire made of synthetic resin material in the control wire, tensile strength and elasticity are improved, and the wire diameter used in the conductive wire and control wire becomes thinner, resulting in a reduction in overall weight and making it lightweight, which facilitates movement and handling, and the weight of the single cable has the effect of reducing worker fatigue. Brief explanation of the drawing

[0032] FIG. 1 is an example diagram showing the installation state of a conventional carbon dioxide gas welding control device. FIG. 2 is a cross-sectional view showing the structure of a conventional carbon dioxide gas welding cable. Figure 3 is a photograph showing the phenomenon where a shielding means attached to the inside of a conventional single cable degrades its flexible function when used for a long period of time. FIG. 4a is a photograph of a real product showing the structure of a carbon dioxide gas welding cable to which the technology of the present invention is applied. FIG. 4b is a cross-sectional view showing the structure of a carbon dioxide gas welding cable to which the technology of the present invention is applied. FIG. 5 is a photograph showing the structure of a power line, which is a technical point of the present invention. FIG. 6a is a photograph showing the structure of a control line, which is a technical point of the present invention. FIG. 6b is a photograph showing the structure of the second control line, which is the technical point of the present invention. FIG. 7 is a cross-sectional view showing the structure of another embodiment of a carbon dioxide gas welding cable to which the technology of the present invention is applied. FIG. 8 is data comparing the current voltage of a conventional single cable and the single cable of the present invention. Specific details for implementing the invention

[0033] A preferred embodiment of the present invention will be described in detail below with reference to the attached drawings.

[0034] The terms described below are defined in consideration of their functions in the present invention, and it is specified that they should be interpreted as concepts consistent with the technical spirit of the present invention and as meanings commonly accepted or recognized in the relevant technical field.

[0035] Hereinafter, the attached drawings are illustrated with exaggerated or simplified portions for the convenience and clarity of explanation, understanding, and understanding of the configuration and operation of the technology, and each component does not exactly correspond to its actual size.

[0036] Figure 4 of the attached drawings is a cross-sectional view showing the structure of a carbon dioxide gas welding cable to which the technology of the present invention is applied. The manufacturing method of the present invention according to this method is a single cable for a carbon dioxide gas welding machine comprising a rubber outer layer (100) made of rubber material, a gas supply pipe (200), a power supply line (300), a control line (400) having an operation control function, and an electromagnetic shielding means (500). Since the rubber outer layer (100) and the gas supply pipe (200) are similar and identical to the conventional structure, the description of their structure is omitted.

[0037] As shown in the attached drawing Fig. 5, the power line (300) is formed by bundling 66 strands of wire diameter 0.18 mm into three bundles, and then twisting the three bundles into one, and as shown in the attached drawings Figs. 4a and 4b, 11 power lines (300) are arranged at regular intervals in the circumferential direction. At this time, the pitch of the twist is formed to be 400 to 800 mm.

[0038] When the wire diameter of the power line (300) is 0.18 mm and the number of strands is formed into 3 bundles of 66 strands, there is a problem in that when the wire diameters are bundled together, a wide gap is formed between the wire diameters and resistance heat is generated due to the wide gap as shown in FIG. 8.

[0039] In the present invention, to reduce heat generated by resistance, using a small wire diameter reduces the gap formed between the wire diameters, thereby drastically reducing heat generated by resistance. In addition, increasing the number of wire diameters while keeping the wires thin can improve strength and provide a current-dividing effect, thereby enabling power factor reduction and resistance reduction.

[0040] In addition, reducing the total weight and decreasing the gaps between wire diameters to reduce the total area of ​​the gaps reduces the generation of high-temperature heat due to resistance.

[0041] The above control line (400) is a structure comprising a first control line (410) formed by twisting 65 strands of plastically twisted wire with a diameter of 0.16 mm to form a single line with a nominal cross-sectional area of ​​1.25 mm², and a second control line (420) comprising an elastic reinforcing yarn (420-2) made of 400 to 500 denier synthetic paper material, preferably PE material, which increases elasticity and elongation strength, when 26 strands of plastically twisted wire with a diameter of 0.16 mm or 20 strands of plastically twisted wire with a diameter of 0.18 mm are twisted to form a single line with a nominal cross-sectional area of ​​0.5 mm².

[0042] To explain the second control line (420) in more detail, one of the following structures is used: a structure formed by twisting 26 strands of plastic wire with a diameter of 0.16 mm to form a single line with a nominal cross-sectional area of ​​0.5 mm², and then adding an elastic reinforcing yarn (420-2) made of a synthetic resin material, preferably PE material with a 400 denier, which increases elasticity and elongation; or a structure formed by twisting 20 strands of plastic wire with a diameter of 0.18 mm to form a single line with a nominal cross-sectional area of ​​0.5 mm², and then adding an elastic reinforcing yarn (420-2) made of a synthetic resin material with a 500 denier that increases elasticity and elongation.

[0043] The first control line (410) is formed by combining two elastic reinforcing yarns (420-2), and seven second control lines (420) are arranged at regular intervals between power lines.

[0044] Here, the elastic reinforcing wire (420-2) made of synthetic resin is formed by being twisted together when forming the second control line (420) as shown in the attached drawing Fig. 6. The reason for using the elastic reinforcing wire (420-2) is to maintain the bent shape when the cable is bent to facilitate welding during welding, and to increase strength to prevent damage caused by fatigue load.

[0045] In addition, the above elastic reinforcing material (420-2) is made of an insulator, so it has the advantage of not affecting electrical properties, and it also has the advantage of being lighter than when the elastic reinforcing material is formed of metal. Therefore, it is preferable to use PE as the material for the above elastic reinforcing material.

[0046] The above electromagnetic shielding means (500) is a structure comprising a coating layer (501) that prevents adhesion to the outer rubber layer (100) and a base member (502) made of any one of non-woven fabric, woven fabric, or spandex on which the coating layer (501) is formed.

[0047] Preferably, spandex is used as the base member (502), and it is preferable to form a coating layer (501) on one side of the spandex. This is because when the cable is bent, the electromagnetic shielding means (500) can freely stretch due to elastic force, thereby providing the advantage of easy bending. In addition, it also has the effect of preventing adhesion to the inner surface of the rubber outer layer (100).

[0048] Meanwhile, the structure of the above gas supply pipe (200) is a structure made of a flexible and soft TPC-ET material as the hose through which the gas travels.

[0049] The present invention, having the structure described above, is manufactured based on a length of 50m. It was found that the total weight of the conventional single cable is reduced by approximately 13–15% as shown in Examples 1 and 2 of Table 2, making it lighter. Furthermore, since the air gap between the wire diameters of the single cable of the present invention is reduced, resistance is generated by the air gap, causing high-temperature heat to be generated. The temperatures corresponding to the high-temperature generation parts are as shown in Table 3 (Example 1) and Table 4 (Example 2). The specifications of the single cable having the structure of the present invention described above and the conventional single cable are compared as follows.

[0050]

[0051] As indicated in Table 2 above, the weight is reduced by 13~15%, so the overall weight is light, making it easy to move and handle, and the weight of the single cable has the effect of reducing worker fatigue.

[0052] Therefore, since the power line supplying the above power has a bundled stranded wire structure, it has the effect of preventing the power line from unraveling.

[0053]

[0054]

[0055] As described above, when examining the current and voltage of each part of the conventional single cable having the structure of Tables 3 and 4 and the cable having the structure of Embodiments 1 and 2 of the present invention, as shown in the attached drawing Fig. 8, it can be seen that the welding current drops to the same level of 14 to 16 A in all cables, and the voltage drop on the welding machine side is maintained at a constant level of 31 V, and it can be seen that the voltage difference between the conventional single cable and the structure of Embodiments 1 and 2 of the present invention is reduced by about 0.2 V.

[0056] The present invention is a useful invention that improves welding quality by reducing the error rate, as the wire diameter used in power lines and control lines becomes thinner, thereby reducing the gap between wire diameters when forming conductive lines and control lines, which in turn reduces the amount of heat generated due to resistance and lowers the heat generation temperature. Additionally, by including an elastic reinforcing wire made of synthetic resin in the control line, tensile strength and elasticity are improved, and the wire diameter used in power lines and control lines becomes thinner, resulting in a reduction in overall weight and making it lightweight, which facilitates movement and handling, and the weight of the single cable has the effect of reducing worker fatigue.

Claims

Claim 1 delete Claim 2 A single cable for a carbon dioxide gas welding machine comprising a rubber outer layer, a gas supply pipe, a power line for power supply, a control line having an operation control function, and an electromagnetic shielding means, wherein the power line is formed by bundling 66 strands of wire diameter 0.18 mm into three bundles, then twisting the three bundles into one and arranging them at regular intervals to reduce the total weight and reduce the formation of gaps between the wire diameters, thereby reducing the generation of high-temperature heat caused by said gaps, and the control line is formed by bundling 65 strands of stranded wire with a diameter of 0.16 mm to form a single line with a nominal cross-sectional area of ​​1.25 mm²; A second control line comprising 26 strands of plastically twisted wire with a diameter of 0.16 mm, which are bundled together to form a single wire with a nominal cross-sectional area of ​​0.5 mm², and including an elastic reinforcing yarn made of a synthetic paper material with a diameter of 400 denier that increases elasticity and elongation; A lightweight and flexible single cable for a carbon dioxide gas welding machine, characterized in that the above-mentioned electromagnetic shielding means comprises a coating layer that prevents adhesion to an outer sheath and a base member made of any one of a non-woven fabric, a woven fabric, or a spandex on which the coating layer is formed. Claim 3 A lightweight and flexible single cable for a carbon dioxide gas welding machine, characterized in that, in claim 2, the coating layer is one of silicone, latex, or rubber. Claim 4 A single cable for a carbon dioxide gas welding machine comprising a rubber outer layer, a gas supply pipe, a power line for power supply, a control line having an operation control function, and an electromagnetic shielding means, wherein the power line is formed by bundling 66 strands of wire diameter 0.18 mm into three bundles, then twisting the three bundles into one and arranging them at regular intervals to reduce the total weight and reduce the formation of gaps between the wire diameters, thereby reducing the generation of high-temperature heat caused by said gaps, and the control line is formed by bundling 65 strands of stranded wire with a diameter of 0.16 mm to form a single line with a nominal cross-sectional area of ​​1.25 mm²; It is composed of a second control wire formed by bundling 20 strands of plastically twisted wire with a diameter of 0.18 mm to form a single wire with a nominal cross-sectional area of ​​0.5 mm², and plying an elastic reinforcing yarn with a diameter of 500 denier made of a synthetic resin material that increases elasticity and elongation; A lightweight and flexible single cable for a carbon dioxide gas welding machine, characterized in that the above-mentioned electromagnetic shielding means comprises a coating layer that prevents adhesion to an outer sheath and a base member made of any one of a non-woven fabric, a woven fabric, or a spandex on which the coating layer is formed. Claim 5 delete

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