Modular power booster and welding gun therefor

Abstract

The application discloses a modular booster and a welding gun thereof. The booster breaks through the limitation of the length of the push wire welding gun in the national standard by being installed at the tail of the handle of the welding gun or being connected in series between welding cables, and expands the traditional 3-meter wire feeding distance to 30 meters or more. The booster breaks the limitation of the activity range of manual welding, so that the operator is no longer restricted by the limited space when working at a large-scale project or a complex work station, and solves the difficulties and pains of frequently moving equipment and adjusting the posture caused by the insufficient wire feeding distance on the site. Meanwhile, the precise wire feeding control structure and the stable power transmission system can significantly improve the wire feeding stability, reduce the welding wire jamming and speed fluctuation, improve the welding seam quality, and improve the welding production efficiency, and are important innovations in the equipment performance and operation mode in the field of manual welding.

Description

Technical Field

[0001] This invention belongs to the technical field of welding torch auxiliary equipment, specifically relating to a modular booster and its welding torch. Background Technology

[0002] In modern welding manufacturing, push-wire welding torches are widely used due to their high efficiency and flexibility. Traditional push-wire welding torches use an external wire feeder to deliver the welding wire. However, due to limitations imposed by the transmission performance of the welding cable and the mechanical transmission system, the wire feeding distance is typically limited to 3 meters. In large-scale engineering projects, the wide welding area and dispersed workstations require operators to frequently move the wire feeder or adjust the torch's position, significantly reducing welding efficiency. Furthermore, long-distance wire feeding is prone to problems such as wire jamming and fluctuations in wire feeding speed, severely impacting weld quality.

[0003] In addition, new welding technologies such as cold metal transfer welding (ASMT) have become the mainstream of high-end manufacturing. They rely on the complex and precise structure of the robotic welding torch to achieve pulsed wire feeding. The robotic welding torch has a complex structure and high cost, which limits its application scenarios. In particular, the robotic welding torch is useless in scenarios such as large structural parts and small welding space. Summary of the Invention

[0004] To address the problems and shortcomings of the existing technologies, this invention provides a modular pusher welding torch that can overcome the limitations of wire feeding distance, adapt to complex welding space layouts, and be compatible with advanced welding processes. This modular pusher welding torch is of great significance for promoting the innovation and development of modern welding manufacturing technology.

[0005] This invention is achieved through the following technical solution:

[0006] A modular booster includes a drive wheel, a driven wheel, and a driver protruding from the housing. The drive wheel is linked to the output shaft of the driver, and the drive wheel and the driven wheel form a wire clamping pair perpendicular to the wire feeding channel axis.

[0007] The wire feeding channel of the same welding equipment can be connected in series with one or more boosters to assist in the wire feeding, according to the actual wire feeding distance requirements.

[0008] The booster can be installed at a preset angle into the wire feeding channel via a connecting mechanism, which includes a fixed connecting part and / or a rotating connecting part.

[0009] Assisted wire feeding overcomes distance limitations: The wire clamping pair formed by the driving and driven wheels, driven by the actuator, generates a continuous and stable pushing force on the welding wire. This structure directly compensates for the insufficient power of traditional wire-feeding guns that rely solely on an external wire feeder, freeing the wire feeding distance from being limited to 3 meters. It can be flexibly extended according to actual operational needs, completely solving the problem of frequent equipment relocation caused by short wire feeding distances in large-scale projects.

[0010] Modular expansion enhances adaptability: The design allows for the connection of multiple boosters in series, enabling segmented supplementation of wire feeding power. For example, in an 18-meter wire feeding distance, connecting two boosters in series can disperse the wire feeding resistance, avoiding excessive load on a single booster. This allows the equipment to adapt to various scenarios, from short-distance precision welding to long-distance large-structure welding, significantly improving its environmental adaptability.

[0011] Adjustable angle enhances operational flexibility: The preset angle installation function of the connecting mechanism can adjust the position of the booster according to the welding torch's working posture (such as different grip angles for overhead and vertical welding). When the welding space is narrow, the angle can be adjusted to avoid interference between the booster and the workpiece, allowing operators to avoid changing their welding posture due to equipment structure limitations, reducing operational difficulty and improving operational safety.

[0012] Furthermore, the booster is fixed to the welding torch handle via a fixing connection, which includes:

[0013] The first connecting member fixed to the housing has angular positioning features;

[0014] The second connector, fixed to the welding torch handle, has a mating structure adapted to the angular positioning features.

[0015] Stable installation ensures operational stability: The fixed connection rigidly connects the booster to the welding torch handle, preventing booster displacement due to equipment vibration during welding. In high-frequency welding operations, this stability reduces fluctuations in wire feeding accuracy caused by positional misalignment, ensuring consistent wire feeding for each weld section.

[0016] Angular positioning ensures efficient power transmission: The angular positioning features of the first and second connectors allow the booster to be installed at multiple angles to the welding torch handle. Specifically, for the booster installed to the welding torch handle, the angle between the axis of its driver (servo motor) and the horizontal plane can be selected in various ways to adapt to complex welding spaces.

[0017] Standardized interfaces simplify the assembly process: The standardized design of the angle positioning features and mating structure eliminates the need for customized accessories when assembling the booster with different models of welding gun handles. Operators can complete the installation simply by aligning the parts, which shortens the equipment debugging time and improves the assembly efficiency in mass production.

[0018] Furthermore, the fixed connection also includes:

[0019] The locking element is configured to lock the first connector and the second connector at a preset angle position.

[0020] The angular positioning feature and mating structure are configured to provide at least one preset angular position, enabling the first connector to be installed to the second connector at a selected preset angle and held in place by a locking element.

[0021] The locking function prevents angle drift: the locking element can maintain a preset angle under welding vibration, collision and other working conditions. For example, in high-intensity operations such as welding on ship decks, even if the welding torch is subjected to external impact, the booster angle will not change, avoiding wire jamming or sudden changes in wire feed speed caused by angle drift.

[0022] Multi-angle selection adapts to complex scenarios: The design of at least one preset angle position enables the equipment to cope with different working environments. For example, when welding pipes, selecting a 30° installation angle allows the booster to avoid the outer wall of the pipe; when welding flat plates, selecting a 0° installation angle reduces the space occupied by the equipment, realizing the flexible application of "one device for multiple scenarios".

[0023] Quick switching improves work efficiency: When changing welding scenarios, simply loosen the locking mechanism to adjust the angle and relock, without disassembling the entire connection structure. Compared to traditional fixed designs, this saves over 50% of angle adjustment time, making it particularly suitable for batch production with multiple workstations.

[0024] Furthermore, the booster, as an independent modular component, is selectively located between the welding torch handle and the welding cable, between two welding cables, or simultaneously between the two. The wire feeding channel axis of the booster is coaxially connected with the wire feeding channel axis of the adjacent component to form a continuous wire transmission path.

[0025] Independent modules simplify maintenance: As independent components, the booster can be disassembled and replaced individually. When a booster fails, the entire welding torch system does not need to be shut down; only the faulty module needs to be replaced to resume operation, reducing equipment downtime to one-third of that of traditional structures.

[0026] Flexible layout optimizes space utilization: The versatility of installation locations allows the equipment to adapt to different space constraints. In compact spaces such as automotive chassis welding, the booster can be integrated into the middle of the cable; in large steel structure welding, it can be installed near the handle for easy operation, achieving optimal allocation of space resources.

[0027] Graded power configuration reduces energy consumption: By segmenting the boosters according to the wire feeding distance (e.g., one booster for up to 3 meters, two boosters for up to 8 meters), the full-load operation of a single booster can be avoided. This graded power output mode can reduce energy consumption by more than 30%, which is in line with the development trend of green manufacturing.

[0028] Furthermore, the drive wheel's shaft is coaxially set with the driver's output shaft. The driver can be set to a unidirectional wire feeding mode or a pulse retraction wire feeding mode. The driver is set as a servo motor to achieve the pulse retraction wire feeding mode.

[0029] Coaxial drive improves power efficiency: The drive wheel shaft and the driver output shaft are coaxially arranged, eliminating energy losses from indirect connections such as gear drives, thus increasing power transmission efficiency to over 95%. For the same wire feeding speed requirements, a lower-power driver can be selected, reducing equipment energy consumption.

[0030] Dual-mode compatibility with diverse welding technologies: The unidirectional wire feeding mode meets conventional welding needs, while the pulse retraction wire feeding mode is suitable for As-Switched Metal Transfer (ASMT) welding. Through precise control of the servo motor, the wire retraction speed can be infinitely adjusted, enabling ordinary welding torches to possess the pulse welding capabilities of robotic welding torches at a low cost.

[0031] Dynamic response optimizes weld quality: The high-speed response characteristics of the servo motor (response time < 0.01s) can compensate for resistance fluctuations during wire feeding in real time. For example, when the welding wire passes through a bent cable, the motor can instantly increase torque to avoid jamming, keeping the wire feeding speed fluctuation within ±1%, and significantly improving the uniformity of weld formation.

[0032] Furthermore, the servo motor of the booster is connected to the controller of the welding machine via a cable.

[0033] Centralized control enhances coordination accuracy: After being linked with the welding machine controller, the wire feeding speed of the booster can be matched with the welding current and voltage parameters in real time.

[0034] Intelligent adjustment adapts to material changes: When welding wires of different materials (such as carbon steel and aluminum alloy), the controller can automatically adjust the clamping force and wire feeding acceleration of the booster according to preset parameters. For example, if the aluminum alloy welding wire is relatively soft, the clamping force can be reduced to avoid deformation, thus improving the adaptability to welding different materials.

[0035] Simplified fault diagnosis streamlines maintenance processes: The controller can monitor the booster's operating parameters (such as motor current and speed) in real time, and immediately alarm and display the fault location when an abnormality occurs. Compared with traditional manual troubleshooting, this shortens fault diagnosis time and reduces equipment maintenance costs.

[0036] Furthermore, the booster also includes a pressure regulator, which comprises a pressure seat hinged to the housing and an adjustment seat fixed to the housing;

[0037] The driven wheel is installed on the pressure seat, and the adjusting seat can change the position of the pressure seat so that the driven wheel moves toward or away from the driving wheel.

[0038] Adjustable pressure to accommodate multiple welding wire specifications: By adjusting the position of the pressure seat, the clamping force can be adjusted within the range of 5-50N to meet the transmission requirements of welding wires with diameters of 0.8-5.2mm. When changing welding wire specifications, there is no need to replace the booster assembly; parameter adjustment can be completed in just 5 minutes, improving the equipment's versatility.

[0039] Stable clamping reduces wire feeding fluctuations: The clamping force can be precisely set for different types of welding wire (e.g., stainless steel welding wire has high hardness, while brass welding wire is easily deformed). For example, a larger clamping force can be applied to stainless steel welding wire to prevent slippage, while a smaller clamping force can be applied to brass welding wire to avoid damage, thus improving wire feeding stability by more than 40%.

[0040] Self-compensating structure extends service life: The hinged design of the pressure seat can automatically adjust the angle when there is a slight bend in the welding wire, avoiding wear of the gear train caused by rigid clamping. In long-term operation, this self-compensating function can extend the service life of the driving and driven wheels to twice that of traditional structures.

[0041] Furthermore, the booster is rotatably connected to the welding cable via a rotating connector, the rotating connector comprising:

[0042] A third connecting member fixed to the housing has a rotating interface;

[0043] The fourth connector, fixed to the welding cable, has a mating interface adapted to the rotating interface.

[0044] The adjustment component is configured to adjust the coupling degree between the third connector and the fourth connector to change the rotational resistance between them;

[0045] The rotating interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable. The adjustment component achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotating interfaces.

[0046] Multi-directional rotation adapts to complex trajectories: The design of the rotation and mating interfaces allows the booster to achieve ±30° pitch angle and ±60° yaw angle adjustment, fully covering the motion trajectory range of the robotic welding torch. When welding the inner wall of large pressure vessels, it can flexibly avoid obstacles with the robotic arm, solving the motion interference problem of traditional fixed structures.

[0047] A modular booster welding torch includes a booster, and the welding torch includes a wire pusher welding torch, a robotic welding torch, and a collaborative robotic welding torch.

[0048] Cross-type compatibility reduces equipment costs: The same booster can be adapted to various types of welding torches, such as wire pusher welding torches and robotic welding torches, eliminating the need for companies to purchase separate booster equipment for different welding torches and reducing equipment procurement costs. For example, manual welding stations and robotic welding stations in automobile factories can share the same model of booster, simplifying spare parts management.

[0049] Technology transfer expands application scenarios: The precision wire feeding technology of robotic welding torches is transferred to ordinary welding torches through boosters, enabling high-end technologies such as cold metal transition welding to be applied to scenarios that are difficult for robots to reach, such as large structural components (such as bridge steel structures) and narrow spaces (such as the inside of pipes), thus promoting the popularization of high-end welding technologies.

[0050] Upgrade and compatibility protect initial investment: Existing welding torches can be upgraded by adding boosters, without needing to replace the original equipment. For example, a traditional wire pusher welding torch can be equipped with a long-distance wire feeding capability after adding a booster, improving the return on initial equipment investment for enterprises.

[0051] Furthermore, the angle between the straight line containing the welding wire inside the booster and the straight line containing the welding wire inside the welding gun handle is 0-30 degrees.

[0052] Angle limitation ensures smooth wire feeding: The included angle range of 0-30° ensures that the transition section of the welding wire between the booster and the welding gun handle is a smooth curve. When the angle exceeds 30°, the welding wire will generate additional resistance due to bending. Limiting the angle can control the increase in resistance to within 10%, avoiding wire jamming.

[0053] Stable path improves welding accuracy: A fixed angle range ensures that the welding wire enters the welding torch nozzle at a consistent position, avoiding arc deviation caused by angle deviation.

[0054] The beneficial effects of this invention are:

[0055] 1. Overcoming wire feeding length limitations to meet long-distance welding requirements:

[0056] Traditional wire-feeding torches are limited by the power and transmission structure of the wire feeder, typically limiting the wire feeding distance to no more than 3 meters. In large-scale engineering welding, frequent relocation of equipment is necessary, severely impacting efficiency. This invention, however, utilizes a modular booster design, allowing one or more boosters to be connected to the wire feeding channel as needed, forming a segmented power supplement. Each booster's drive and driven wheels work together to provide continuous propulsion, effectively counteracting the resistance of long-distance wire feeding. This easily extends the wire feeding length beyond 10 meters, fully covering the welding range of large structures such as bridges, ships, and large pressure vessels. It completely solves the problem of short wire feeding distances in traditional equipment, significantly reducing equipment relocation and improving operational continuity.

[0057] 2. Flexible wire feeding modes to adapt to diverse welding technologies:

[0058] The booster's driver can be flexibly switched between unidirectional wire feeding mode and pulse retraction wire feeding mode by replacing the unidirectional motor or servo motor. Unidirectional wire feeding mode meets the stable wire feeding requirements of conventional welding, ensuring uniform wire delivery; while pulse retraction wire feeding mode enables precise wire retraction and pushing, perfectly adapting to high-end technologies such as ASMT (Assembled Assembled Metal Touch) welding. This function allows ordinary wire pusher welding torches to complete precision welding operations without relying on complex and expensive robotic structures, breaking the dependence of high-end welding technologies on specialized equipment and enabling ASMT technology to be applied in scenarios such as large structural components and confined spaces.

[0059] 3. Multi-angle installation design to adapt to complex working spaces:

[0060] The welding booster can be installed at multiple angles via a connecting mechanism (including a fixed connection and a rotating connection). It can be fixedly installed to the welding torch handle at a preset angle, and the rotating connection allows the booster to rotate in multiple directions relative to the welding cable. In complex scenarios such as circumferential welding inside pipes or welding in confined spaces within equipment, operators can flexibly adjust the booster angle according to the working environment, avoiding interference with the workpiece or surrounding equipment, ensuring a smooth welding process, and significantly improving the equipment's adaptability in complex spaces.

[0061] 4. Other significant advantages:

[0062] Lowering equipment costs and upgrading barriers: Compared to dedicated robotic welding torches, the modular design of this invention significantly reduces manufacturing costs. Existing wire pusher welding torches can be upgraded simply by adding an assist device, without the need to replace the entire equipment, thus greatly reducing enterprise investment.

[0063] Improve welding quality and efficiency: Segmented wire feeding helps control the wire feeding speed fluctuation within ±1%, reducing wire jamming and breakage, and improving welding quality.

[0064] Enhanced equipment compatibility and ease of maintenance: As an independent modular component, the booster can be adapted to various equipment such as wire pusher welding guns, robotic welding guns, and collaborative robotic welding guns, making it highly versatile; moreover, its simple structure allows for individual disassembly and replacement during later maintenance, reducing downtime and lowering maintenance costs.

[0065] In summary, this invention addresses core issues such as wire feeding length, mode switching, and space adaptability, while combining advantages in cost, efficiency, and compatibility, providing the welding industry with an efficient, flexible, and economical solution and driving the development of welding equipment towards multifunctionality and wide adaptability. Attached Figure Description

[0066] Figure 1 A connection diagram illustrating an illustrative embodiment of the welding torch with a horizontal booster installed in this invention;

[0067] Figure 2 A schematic diagram illustrating one embodiment of the horizontal booster in this invention;

[0068] Figure 3 A schematic structural diagram illustrating a cross-sectional view of the horizontal booster in this invention;

[0069] Figure 4 A schematic diagram illustrating one embodiment of the vertical booster in this invention;

[0070] Figure 5 A schematic structural diagram illustrating a cross-sectional view of the vertical booster in this invention;

[0071] Figure 6 A schematic diagram illustrating another embodiment of the vertical booster in the present invention in its cut-out state;

[0072] Figure 7 A connection diagram illustrating an illustrative embodiment of the collaborative robot welding torch with a horizontal booster installed in this invention;

[0073] Figure 8 A connection diagram illustrating an illustrative embodiment of the robotic welding torch with a horizontal booster installed in this invention;

[0074] Figure 9 This is a schematic diagram illustrating a typical embodiment of a conventional welding torch with a vertical booster installed in this invention.

[0075] List of components and reference numerals:

[0076] 1. Housing; 11. First half-shell; 12. Second half-shell; 13. Transparent cover; 2. Drive wheel; 3. Driven wheel; 4. Driver; 5. Connecting mechanism; 51. Fixed connection part; 511. First connecting piece; 512. Second connecting piece; 513. Locking piece; 52. Rotating connection part; 521. Third connecting piece; 522. Fourth connecting piece; 523. Adjusting assembly; 6. Wire feeding channel; 61. Welding torch handle; 62. Welding cable; 7. Operation panel; 71. Voltage adjustment control; 72. Current adjustment control; 8. Welding wire; 9. Pressure regulator; 91. Pressure seat; 911. Support shaft; 912. Pressure shaft; 913. Pin; 92. Adjusting seat; 921. Adjusting slide rod; 922. Slide rod limiter; 923. Pressure rod; 924. Tension spring. Detailed Implementation

[0077] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0078] It should be noted that the directional terms such as left, right, up, down, front, and back in the embodiments of the present invention are only relative concepts or are based on the normal use state of the product, i.e., the direction of the product's movement, and should not be considered as limiting.

[0079] In addition, it should be noted that the dynamic terms such as "relative motion" mentioned in the embodiments of the present invention refer not only to changes in position, but also to movements such as rotation and rolling in which the position does not change relative to the position, but the state changes.

[0080] Finally, it should be noted that when a component is said to be "located on" or "set on" another component, it can be on the other component or may have an intervening component at the same time. When a component is said to be "connected to" another component, it can be directly connected to the other component or may have an intervening component at the same time.

[0081] In existing technologies, wire pusher welding torches generally adopt an external wire feeder structure. Due to the limitations of the welding cable transmission performance, the wire feeding distance is difficult to exceed 3 meters. Although some wire pusher welding torches have an auxiliary wire feeder inside the torch handle, which can play a certain role in assisting wire feeding, there are obvious limitations: on the one hand, due to the size limitation of the torch handle, the motor model of the auxiliary wire feeder is strictly limited and cannot provide a strong wire feeding force; on the other hand, existing auxiliary wire feeders are mostly integrated with the torch handle, built into the handle and cannot be separated, resulting in extremely poor flexibility and making them unsuitable for use between two welding cable sections.

[0082] In comparison, this application adopts a modular design, and the power of the driver is much greater than the output power of the motor built into the welding torch handle. In addition, the auxiliary wire feeder in the traditional welding torch handle is only driven in one direction by the motor and only supports unidirectional wire feeding. It cannot adapt to new processes such as cold metal transition welding that require pulse retraction wire feeding, while this application can effectively solve this problem.

[0083] This invention discloses a modular booster and its welding torch. The booster is an independent modular component with flexible installation location options: it can be placed between the welding torch handle 61 and the welding cable 62, connected in series between two sections of welding cable 62, or installed in both locations simultaneously. Its wire feeding channel 6 axis is coaxially aligned with the wire feeding channel 6 axis of adjacent components, forming a continuous wire 8 transmission path to meet long-distance welding requirements. One or more boosters can be connected in series to the wire feeding channel 6 of the same welding equipment according to the actual wire feeding distance requirements. Its core function is to effectively overcome the wire feeding distance limitations of traditional push-wire welding torches through multi-stage auxiliary propulsion. A single booster can enhance local wire feeding power; multiple boosters connected in series can form a relay-type wire feeding drive, significantly extending the wire feeding range and breaking through the national standard limitation on the length of push-wire welding torches, thus extending the traditional 3-meter wire feeding distance. This power-up device breaks through the limitations of manual welding, freeing operators from spatial constraints when working on large projects or complex workstations. It solves the difficulties and pain points of frequent equipment relocation and posture adjustment caused by insufficient wire feeding distance on site, and improves the continuity and efficiency of welding operations.

[0084] In addition, the booster can be used independently and mounted on a standard welding torch (such as...). Figure 1 ), robotic welding torch (such as Figure 8 ) or collaborative robot welding torch (such as Figure 7 On the other hand, it can effectively improve the stability of wire feeding, thereby stabilizing arc combustion, reducing splashing, and significantly expanding the range of motion of collaborative robots.

[0085] This application makes the following... Figures 1 to 9 This diagram illustrates a modular booster and its welding torch. The booster is a miniaturized compression wire feeding device. Within its housing 1, a drive wheel 2 and a driven wheel 33 form a wire clamping pair for the welding wire 8. The rims of the wire feeding wheels (drive wheel 2 and driven wheel 3) are machined with V-grooves or U-grooves to accommodate steel and aluminum wire feeding, respectively. This increases the friction between the wire feeding wheels and the welding wire 8 and also guides the welding wire 8. The booster device uses a driver 44 (usually a conventional motor) to drive the wire feeding wheels, feeding the welding wire 8 to the welding torch. Replacing the conventional motor with a servo motor changes the wire feeding mode from unidirectional to pulse-backfeed ("more in, less out" feeding mode), thus adapting to ASMT welding processes and significantly expanding its application range. The precise wire feeding control structure and stable power transmission system in the booster can significantly improve wire feeding stability, reduce wire jamming and speed fluctuations, improve weld formation accuracy and product quality, and increase welding production efficiency. It is an important innovation in equipment performance and operation mode in the field of manual welding.

[0086] The booster is mounted at a preset angle on the wire feeding channel 6 via a connecting mechanism 5, which includes a fixed connection part 51 and / or a rotating connection part 52. The fixed connection part 51 enables a rigid connection between the booster and the wire feeding channel 6, ensuring the consistency of the wire feeding axis through a stable structural fit. This fundamentally avoids wire feeding deviations caused by loose connections, ensuring accurate wire feeding path for the welding wire 8. For example, in welding scenarios with limited space, the booster can be pre-fixed to the welding torch handle 61 according to the actual working space. The rigid connection prevents the protruding driver 4 on the booster from colliding and interfering with the workpiece, ensuring operational safety and stability.

[0087] The rotating connection 52 provides the booster with flexible angle adjustment capabilities, enabling it to adapt to different wire feeding channels 6 or complex welding environments. By dynamically adjusting the angle to match changes in the welding torch posture and working space, it ensures that the welding wire 8 can still advance smoothly even in complex feeding paths such as bends and turns, significantly improving the equipment's adaptability to diverse welding scenarios. For example, when the booster and welding cable 62 are connected by a ball joint, a certain bending allowance can be formed between the welding torch handle 61 and the welding cable 62, allowing the operator to adjust the welding torch angle more naturally during operation, effectively improving the comfort of welding operations.

[0088] A modular booster, the technical solution of which consists of four parts: structural design, installation system, drive control and functional expansion.

[0089] In terms of structural design, a combination of a vertical wire clamping pair and a split housing 1 is adopted. The driving wheel 2 and the driven wheel 3 are arranged perpendicular to the axis of the wire feeding channel 6, and the constraint on the wire 8 is enhanced by orthogonal clamping. V-grooves or U-grooves are machined at the rims of the wire feeding wheels to suppress deviation and shaking during the wire feeding process. The first half-shell 11 and the second half-shell 12, which are separated along the axis of the wire feeding channel 6, are connected by a detachable sealed structure, which facilitates the quick inspection and replacement of internal components, while ensuring the protective performance of the equipment.

[0090] The installation system integrates a dual connection mechanism of fixed and rotating components. The fixed connection part 51, through its angular positioning features, mating structure, and locking element 513, enables precise multi-position angle adjustment of the booster on the welding torch handle 61, ensuring posture adaptation during operation in confined spaces. The rotating connection part 52, utilizing its rotating interface, mating interface, and adjustment component 523, provides the booster with multi-directional rotational freedom at the welding cable 62 connection point, and allows for adjustment of rotational resistance as needed, meeting the posture adjustment requirements during dynamic welding processes.

[0091] The drive control system features bidirectional wire feeding capability and modular expansion characteristics. The output shaft of the driver 4 is coaxially and directly connected to the drive wheel 2, supporting dual-mode switching between unidirectional wire feeding and pulse retraction wire feeding. The pulse retraction mode precisely matches the requirements of new welding processes such as cold metal transition through periodic wire feeding and retraction actions. The booster, as an independent modular component, can be flexibly deployed at locations such as between the welding torch handle 61 and the cable, and at cable segmentation points. Multiple boosters can be cascaded and networked through standardized connectors, effectively extending the wire feeding distance and constructing a continuous and stable wire 8 transmission path.

[0092] The functional expansion module further enhances the equipment's applicability and ease of operation. The integrated operation panel 7, with its voltage, current, wire feed speed adjustment, and mode switching functions, enables one-stop precise control of welding parameters. The hinged transparent cover 13 design facilitates both real-time monitoring of the working status and convenient equipment maintenance. The pressure regulator 9 dynamically adjusts the clamping pressure of the driven wheel 3 according to the diameter and material of the welding wire 8, broadening the equipment's applicability. Various power boosters with standardized connectors allow for quick adaptation, reducing equipment selection and maintenance costs.

[0093] The driving roller 2 is a roller powered by the driver 4, and its surface has anti-slip textures to increase friction with the welding wire 8. The driven roller 3 is a passive roller that works with the driving roller 2 to clamp the welding wire 8, maintaining the clamping force with the driving roller 2 through elastic pressure. The driver 4 is a drive device that provides wire feeding power, which can be implemented using a servo motor. Its output shaft is coaxially connected to the driving roller 2 to reduce transmission losses. The booster can be 360° circumferentially mounted on the wire feeding channel 6, and can be rotated at any angle relative to the axis of the wire feeding channel 6 for mounting and fixing.

[0094] Specifically, the wire feeding roller assembly formed by the driving wheel 2 and the driven wheel 3 is arranged perpendicular to the axis of the welding wire 8, ensuring stable feeding of the welding wire 8 during clamping and conveying. The driver 4 is mounted to the housing 1 and offset to one side, forming a partially protruding structure. When the booster is installed in the wire feeding channel 6, the operator can rotate the booster to orient the protrusion (driver 4) toward an unobstructed space. For example, in pipe welding, the protrusion (driver 4) can be adjusted to a recessed area on the inner wall of the pipe to avoid collision, and then the housing 1 and the wire feeding channel 6 can be fixed. Both ends of the housing 1 can be connected to the wire feeding channel 6 via hinges or ball joints, allowing the booster to swing or rotate freely in a specific direction. It can also be installed to the welding torch handle 61 of the wire feeding channel 6 by means of a fixed clip.

[0095] Through the above technical solution, this application solves the problem of wire jamming during long-distance wire feeding, extending the wire feeding distance to up to thirty meters. The circumferentially adjustable installation method avoids interference between the booster and surrounding structures, making it suitable for welding in confined spaces such as inside pipelines. The driver 4 supports switching between unidirectional wire feeding and pulse retraction modes, adapting to the wire feeding accuracy requirements of cold metal transition welding processes.

[0096] This application further proposes that the booster is fixed to the welding torch handle 61 via a fixing connection part 51, the fixing connection part 51 including:

[0097] The first connecting member 511, which is fixed to the housing 1, has an angular positioning feature;

[0098] The second connector 512, which is fixed to the welding gun handle 61, has a mating structure adapted to the angle positioning features;

[0099] The locking member 513 is configured to lock the first connecting member 511 and the second connecting member 512 at a preset angle position;

[0100] The angular positioning feature and mating structure are configured to provide at least one preset angular position, enabling the first connector 511 to be installed to the second connector 512 at a selected preset angle and held in place by the locking member 513.

[0101] In one embodiment, the housing 1 of the modular booster is made of high-temperature resistant engineering plastic and is flat and elongated. A first connector 511 is integrally formed on the outer wall of the housing 1 facing the welding torch handle 61. The first connector 511 is a rectangular plate, and its surface away from the housing 1 has angle positioning features, specifically three evenly distributed semi-circular grooves corresponding to three preset angle positions of 0°, 15°, and 30°. The inner walls of the grooves are smooth and have a certain depth, enabling stable angle positioning.

[0102] The welding torch handle 61 is made of traditional insulating material. A second connector 512 is fixed to it with screws near the booster housing 1. The second connector 512 is also a rectangular plate that matches the first connector 511. Its surface facing the first connector 511 has a mating structure, namely a resiliently expandable convex ball. The diameter of the convex ball matches the diameter of the semi-circular groove on the upper part of the first connector 511, and it can fit perfectly into the groove to achieve an angular fit between the two.

[0103] The locking component 513 uses a wing bolt. The first connector 511 and the second connector 512 are both provided with corresponding bolt holes. The position of the bolt holes avoids the angle positioning features and mating structure to ensure that the angle positioning function is not affected.

[0104] During installation, a suitable preset angle is selected based on the space requirements and operating habits of the actual welding operation. If a 15° angle is selected, align the semi-circular groove corresponding to 15° on the first connector 511 with the protruding ball on the second connector 512, and gently press. The protruding ball will embed itself into the groove under the action of elasticity, achieving initial angle positioning. Subsequently, pass the wing bolt through the bolt holes on the first connector 511 and the second connector 512 and tighten it. The tightening force of the bolt securely locks the first connector 511 and the second connector 512 at the preset 15° angle position, preventing angle displacement due to vibration or other factors during the welding operation.

[0105] When the angle position needs to be changed, simply loosen the wing bolt to allow the metal convex ball to dislodge from the current groove, then adjust the first connector 511 to the groove position corresponding to the required angle, re-insert the convex ball, and tighten the bolt. The operation is convenient and flexible.

[0106] With this structural design, the booster can be stably and flexibly mounted on the welding torch handle 61 at a preset angle, adapting to different welding operation scenarios and improving the convenience of operation and the stability of welding.

[0107] In one embodiment, the first connecting member 511 can be configured as a first flange plate, the second connecting member 512 as a second flange plate, and the locking member 513 as a bolt. Both the first and second flange plates have circumferentially arranged positioning holes. The specific application method is a conventional bolt connection method, which will not be described in detail.

[0108] In one embodiment, during pressure vessel welding operations, the booster needs to be installed at a 90° vertical angle onto the welding torch handle 61. The first connector 511 is an annular toothed disc structure, fixed to the end of the booster housing 1, with 36 evenly distributed positioning teeth around its circumference as angular positioning features. The second connector 512 is a corresponding toothed groove structure, fixed to the mounting end face of the welding torch handle 61, with the toothed groove perfectly matching the shape and size of the positioning teeth on the toothed disc. During installation, the toothed disc is embedded into the toothed groove, and different tooth positions can be selected by rotating the toothed disc to achieve multiple preset angle installations such as 0°, 90°, 180°, and 270°. After selecting a 90° angle, bolts and nuts are used as locking elements 513, passing through the corresponding through holes on the toothed disc and toothed groove and tightening them to ensure a tight engagement between the toothed disc and toothed groove. This ensures the booster maintains a fixed angle under welding vibration conditions, effectively preventing welding accuracy from being affected by angle deviation.

[0109] This application further proposes that the booster be set as an independent modular component, selectively disposed between the welding torch handle 61 and the welding cable 62, between two sections of welding cable 62, or simultaneously disposed between the two, and the wire feeding channel 6 axis of the booster is coaxially connected with the wire feeding channel 6 axis of the adjacent component to form a continuous wire 8 transmission path.

[0110] In one embodiment, the booster is installed only between the welding torch handle 61 and the welding cable 62. The welding torch handle 61 refers to the main body of the welding tool held by the operator, which can be manufactured using injection molding or metal casting processes, and has an internal guide channel for the welding wire 8. The welding cable 62 is a flexible tubular structure that wraps around the welding wire 8 and transmits electricity, which can be implemented using a composite structure of multiple layers of metal braid and an insulating sheath, used to protect the welding wire 8 and conduct welding current. The booster being installed only between the welding torch handle 61 and the welding cable 62 means that both ends of the booster's housing 1 are connected to the end of the welding torch handle 61 and the outlet end of the welding cable 62, respectively. This can be achieved using flange connections or snap-on quick-release structures, thus optimizing the linearity of the wire feeding path by limiting the booster's installation position.

[0111] Through the above technical solution, this application solves the problems of wire jamming and unstable wire feeding speed during long-distance wire feeding, while ensuring the compact installation of the booster at the connection between the welding gun handle 61 and the welding cable 62, so that it can adapt to the space-constrained working environment such as pipeline welding.

[0112] In one embodiment, the booster is installed only between the two welding cable segments 62. The wire feeding channel 6 refers to the transmission path of the welding wire 8 from the wire feeder to the end of the welding torch. Specifically, it can be implemented using a continuous structure including a welding torch handle 61 and welding cable 62. The welding torch handle 61 is used for gripping and operation, and the welding cable 62 is used for power transmission and wire 8 delivery. The area between the two welding cable segments 62 refers to the connection area formed by dividing the welding cable 62 into a front and rear section. This can be achieved by providing a detachable connector or a segmented sleeve structure in the middle section of the welding cable 62.

[0113] Specifically, by installing the booster between the two welding cable segments 62, the connection area between the welding torch handle 61 and the welding cable 62 maintains a simple structure. The booster housing 1 is fixed to the outer wall of the welding cable 62 via a flange or snap-fit ​​structure, and the wire feed roller assembly clamps the welding wire 8 and drives it to move along the wire feed channel 6. Since the booster is not directly connected to the welding torch handle 61, the rotation angle of the welding torch handle 61 is not limited by the booster's size when the operator is working in confined spaces. Furthermore, the segmented structure of the welding cable 62 allows for adjustment of the booster's installation position according to working conditions.

[0114] Compared to existing technologies, traditional welding torch boosters are typically integrated near the welding torch handle 61, resulting in an increased handle size and susceptibility to interference with surrounding structures. This solution, by relocating the booster to the middle section of the welding cable 62, maintains the compactness of the welding torch handle 61 while utilizing the flexibility of the welding cable 62 to adapt to different spatial layouts. For example, when welding inside a pipe, the booster can be installed away from bending areas to avoid collisions with the pipe wall.

[0115] Through the above technical solutions, this application solves the problem of difficult installation of the booster in narrow spaces, reduces the risk of spatial interference when operating the welding torch handle 61, and enables flexible adjustment of the booster position through the segmented design of the welding cable 62, meeting the need for free switching of the welding torch posture in long-distance wire feeding scenarios.

[0116] Installing boosters at the connection between the welding torch handle 61 and the welding cable 62 directly enhances the wire feeding drive force near the welding torch handle 61, reducing speed fluctuations of the welding wire 8 before entering the welding torch handle 61. Adding boosters between the two sections of the welding cable 62 can compensate for the attenuation of drive force during long-distance wire feeding in segments. By installing boosters at multiple locations, the welding wire 8 forms a segmented drive mode within the wire feeding channel 6, with each booster working independently and collaboratively maintaining the continuity of wire feeding. For example, after the welding wire 8 passes the boosters between the welding cables 62, it is driven by the boosters between the two sections of the welding cable 62 when entering the welding torch handle 61, avoiding jamming of the welding wire 8 due to insufficient power from a single drive source.

[0117] Compared to existing technologies, traditional welding torch boosters are only installed between the welding torch handle 61 and the welding cable 62, which cannot cover the wire feeding requirements of a long welding cable 62 segment, leading to insufficient driving force for the welding wire 8 within the welding cable 62 segment. This solution, by adding a booster between the two welding cable segments 62, distributes the wire feeding driving force along the length of the welding cable 62, effectively solving the problem of long-distance wire feeding stability. Furthermore, traditional boosters, due to their single installation location, are prone to interference with surrounding structures in confined spaces, while this solution allows for distributed installation of boosters, enabling flexible layout adjustments based on space constraints.

[0118] Through the above technical solutions, this application can significantly extend the effective working distance of the wire feeding channel 6 and reduce the speed fluctuation of the welding wire 8 during long-distance transportation. At the same time, the segmented installation method of the booster on the welding cable 62 segments can adapt to the space constraints of different welding scenarios, avoid installation interference caused by the excessive size of a single booster, and thus improve the adaptability of the welding equipment in complex working environments.

[0119] This application further proposes that the shaft of the drive wheel 2 and the output shaft of the driver 4 are coaxially arranged. The driver 4 can be set to a unidirectional wire feeding mode or a pulse retraction wire feeding mode. The driver 4 is set as a servo motor to realize the pulse retraction wire feeding mode. The pulse retraction wire feeding mode is configured to control the output shaft to perform periodic wire feeding and retraction actions in a progressive manner.

[0120] The coaxial arrangement of the drive wheel 2's rotation axis and the driver 4's output shaft means that the rotation axis of the drive wheel 2 coincides with the power output axis of the driver 4. This can be achieved using a direct-drive transmission structure or an integrated shaft structure, thereby reducing the transmission chain length and power loss. The unidirectional wire feeding mode means that the driver 4 drives the drive wheel 2 to rotate in only one direction to continuously feed the welding wire 8. This can be achieved using a unidirectional electromagnetic clutch or a directional control circuit, thus maintaining the stable wire feeding requirements of traditional welding processes. The pulse-retraction wire feeding mode means that the driver 4 periodically switches the forward and reverse rotation of the drive wheel 2 to intermittently advance and retract the welding wire 8. This can be achieved using a servo motor in conjunction with a pulse control program, thus adapting to the dynamic adjustment requirements of the welding wire 8 in cold metal transition welding processes.

[0121] Specifically, the driver 4 directly drives the drive wheel 2 to rotate via a coaxial transmission structure. In unidirectional wire feeding mode, the drive wheel 2 pushes the welding wire 8 continuously along the wire feeding channel 6 at a constant speed. In pulse retraction wire feeding mode, the driver 4 generates periodic pulse signals according to welding parameter requirements, controlling the drive wheel 2 to alternately perform forward rotation wire feeding and reverse rotation retraction actions. Thus, the welding wire 8 forms intermittent advance and slight retraction in the wire feeding channel 6, thereby precisely controlling the droplet transfer process and avoiding the molten pool disturbance problem caused by traditional unidirectional wire feeding. It should be noted that the unidirectional wire feeding mode or pulse retraction wire feeding mode can be switched by changing the driver.

[0122] This solution simplifies the transmission path through a coaxial direct connection design and integrates bidirectional control functionality, allowing for flexible switching of the wire feeding mode according to welding process requirements. This application solves the technical problem that traditional boosters cannot adapt to pulse-retracted wire feeding processes. Through bidirectional wire feeding control, it achieves precise adjustment of the wire's trajectory, meeting the dynamic changes in wire feeding speed required for cold metal transition welding, thereby improving weld formation quality and process stability.

[0123] This application further proposes that the servo motor of the booster is connected to the controller of the welding machine via a cable. Specifically, the booster is provided with an operation panel 7 that is communicatively connected to the controller of the welding machine. The operation panel 7 includes a voltage adjustment control 71, a current adjustment control 72, a wire feed speed adjustment control, and a wire feed mode switching control. The wire feed mode switching control is configured to switch between unidirectional wire feed mode and pulse retraction wire feed mode, and each control coordinates to adjust the wire feed parameters.

[0124] In one embodiment, the welding of aluminum alloy sheet for a new energy vehicle battery casing 1 requires extremely high control over welding heat input. The operator first adjusts the booster to pulse-retract wire feeding mode using the wire feed mode switching control to reduce heat input during welding and prevent sheet deformation. Then, based on the thickness of the aluminum alloy sheet, the welding voltage is set to a lower level using the voltage adjustment control 71 to reduce arc energy; finally, the welding current is fine-tuned using the current adjustment control 72 to ensure arc stability.

[0125] Regarding wire feeding speed adjustment, since the welding wire 8 needs to frequently perform feeding and retraction actions in the pulse-retraction wire feeding mode, the operator sets the wire feeding speed adjustment control to a moderate value based on the welding speed, so that the welding wire 8 is accurately fed to the appropriate length in each pulse cycle. Throughout the welding process, voltage, current, wire feeding speed, and wire feeding mode work together, and the controls are adjusted in a coordinated manner, resulting in a minimal heat-affected zone, aesthetically pleasing weld formation, and welding deformation controlled within 1mm, effectively ensuring the welding quality and sealing of the battery casing 1.

[0126] This application further proposes that the booster also includes a pressure regulator 9, which includes a pressure seat 91 hinged to the housing 1 and an adjustment seat 92 fixed to the housing 1. Specifically, one end of the pressure seat 91 is hinged to the housing 1 via a pin 913, a driven wheel 3 is installed in the middle, and a support shaft 911 and a pressure shaft 912 are respectively provided on both sides; the adjustment seat 92 is provided with a slidable adjustment slide rod 921, a slide rod limiter 922 that limits the adjustment slide rod 921, and a pressure rod 923 hinged to the adjustment slide rod 921; one end of the pressure rod 923 is sleeved on the support shaft 911, and its side wall abuts against the pressure shaft 912; the adjustment slide rod 921 is sleeved with a connecting tension spring 924, and the tension spring 924 drives the pressure rod 923 to press the pressure shaft 912.

[0127] The pressure regulator 9 is a device that dynamically adjusts the pressure applied to the welding wire 8 by the driven wheel 3 through a mechanical structure. Specifically, it can be implemented using a combination of a hinged lever and an elastic element. The pressure seat 91 forms a fulcrum through the hinge point, and the support shaft 911 and pressure shaft 912 serve as the force receiving point and force application point, respectively, to realize the transmission and adjustment of the pressure on the driven wheel 3. The adjusting slide rod 921 is a guide component that moves linearly along the adjusting seat 92. Specifically, it can be implemented using a metal rod with a limiting groove. The slide rod limiter 922 limits the position of the slide rod through a threaded knob or snap-fit ​​structure, thereby controlling the swing amplitude of the pressure rod 923. The tension spring 924 is an element that provides elastic restoring force. Specifically, it can be implemented using a helical spring or a leaf spring. Its two ends are connected to the adjusting slide rod 921 and the adjusting seat 92, respectively. The preload drives the pressure rod 923 to continuously apply pressure to the pressure shaft 912, ensuring a stable clamping force between the driven wheel 3 and the driving wheel 2.

[0128] Specifically, the pressure seat 91 forms a rotatable connection with the housing 1 through a hinge point. When the adjusting slide rod 921 slides along the adjusting seat 92, the pressure rod 923 changes angle around the support shaft 911, thereby changing the thrust of the pressure shaft 912 on the pressure seat 91. The slide rod limiter 922 locks and limits the swing angle of the pressure rod 923 by fixing the position of the adjusting slide rod 921, thereby controlling the clamping pressure between the driven wheel 3 and the driving wheel 2. The preload of the tension spring 924 keeps the pressure rod 923 in close contact with the pressure shaft 912. When the diameter of the welding wire 8 changes or the wire feeding resistance fluctuates, the pressure seat 91 can adaptively adjust its angle to maintain the dynamic balance of the clamping force.

[0129] This solution uses the linkage mechanism of slide bar and pressure bar 923, combined with the elastic buffer of tension spring 924, to make the pressure adjustment process adaptive. When the diameter of welding wire 8 changes or the wire feeding resistance changes abruptly, it can automatically balance the clamping force and avoid the welding wire 8 from getting stuck between the driving wheel 2 and the driven wheel 3 due to fixed pressure.

[0130] Through the above technical solution, this application solves the problem of wire jamming caused by unstable clamping force during long-distance wire feeding, while adapting to the wire feeding requirements of different diameter welding wires 8, reducing the frequency of manual adjustment, and improving the continuity of welding operations. In complex space operations, the pressure parameters are quickly locked by the slide bar limiter 922 to avoid clamping force failure due to external interference, ensuring consistent welding quality.

[0131] This application further proposes that the booster is rotatably connected to the welding cable 62 via a rotatable connection part 52, the rotatable connection part 52 comprising:

[0132] The third connecting member 521, which is fixed to the housing 1, has a rotating interface;

[0133] The fourth connector 522, which is fixed to the welding cable 62, has a mating interface adapted to the rotating interface.

[0134] Adjustment component 523 is configured to adjust the coupling degree between the third connector 521 and the fourth connector 522 to change the rotational resistance between them;

[0135] The rotating interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable 62. The adjustment component 523 achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotating interfaces.

[0136] In one embodiment, during the welding of curved surfaces of a ship's hull, the booster needs to flexibly adjust its posture to fit the complex weld seam. The third connector 521 is a hemispherical boss structure, fixedly installed at the bottom of the booster housing 1, with the hemispherical surface serving as the rotation interface and the surface being precision polished; the fourth connector 522 is a corresponding hemispherical groove structure, fixed to the end of the welding cable 62, with a wear-resistant polytetrafluoroethylene liner embedded in the inner wall of the groove, forming a mating interface adapted to the rotation interface.

[0137] The adjustment assembly 523 employs a disc spring group and a screw mechanism. A blind hole is provided inside the hemispherical boss. The screw passes through the blind hole and mates with a threaded hole at the bottom of the hemispherical groove. Multiple disc springs are sleeved on the screw, located between the bottom of the blind hole of the boss and the bottom surface of the groove. When the screw is rotated, the disc springs are compressed or released, changing the normal force between the boss and the groove, thereby adjusting the rotational resistance. During welding, the booster can rotate freely in the pitch, yaw, and roll directions. The welder can easily adjust their posture according to the weld direction. By tightening or loosening the screw, the rotational resistance can be increased or decreased as needed, ensuring that the booster can be flexibly adjusted and remain stable in welding complex curved surfaces, significantly improving welding efficiency and accuracy.

[0138] In one embodiment, a compact and efficient rotating connection part 52 is designed for the confined space operation scenario of welding automotive parts. The third connector 521 is a small cross-shaft universal joint structure, one end of which is rigidly connected to the booster housing 1, and the four journals of the cross-shaft serve as the rotation interface; the fourth connector 522 is a matching fork-shaped connector, which is fixed to the welding cable 62, and the fork of the fork-shaped connector is adapted to the journal of the cross-shaft to form a mating interface.

[0139] The adjustment component 523 employs a magnetorheological fluid damper. A sealed cavity filled with magnetorheological fluid is located at the center of the universal joint's cross shaft, and an electromagnetic coil is wound around the perimeter of the cavity. By adjusting the current in the electromagnetic coil, the viscosity of the magnetorheological fluid is changed, thereby adjusting the contact characteristics between the rotating interfaces and achieving rapid adjustment of rotational resistance. During automotive chassis welding, the booster can rotate flexibly in multiple directions via the universal joint, adapting to different welding angles in confined spaces. When a fixed posture is required for precision welding, increasing the current in the electromagnetic coil increases the viscosity of the magnetorheological fluid, increasing rotational resistance, and the booster immediately stabilizes at the desired position, effectively solving the problem of inconvenient welding operations in confined spaces.

[0140] In one embodiment, in the welding of large-scale engineering machinery structures, a durable rotating connection 52 is designed to cope with long-term high-intensity welding operations. The third connector 521 is a ball joint structure, with the ball part fixed to the side of the booster housing 1, and the spherical surface serving as the rotation interface; the fourth connector 522 is a connector seat with a ball socket, which is installed on the welding cable 62, and the inner wall of the ball socket is lined with copper-based powder metallurgy friction pads to form a mating interface.

[0141] The adjusting assembly 523 consists of an annular gland, an adjusting bolt, and a spring. After the ball of the ball joint passes through the socket, it is limited by the annular gland. The adjusting bolt passes through the annular gland and is threaded into the connecting seat. The spring is fitted onto the adjusting bolt and located between the annular gland and the connecting seat. Tightening the adjusting bolt compresses or releases the spring, changing the pressure of the annular gland on the ball, thereby adjusting the friction between the ball and the friction plate, achieving adjustment of rotational resistance. In the welding process of engineering machinery, the booster relies on the ball joint to achieve multi-directional rotation, meeting the welding needs of different parts. By adjusting the adjusting bolt, the rotational resistance can be precisely set according to the welder's operating habits and welding conditions. Even under long-term vibration environments, the booster can maintain a stable posture, ensuring welding quality.

[0142] This application also proposes that the housing 1 adopts a split structure extending along the axial direction of the wire feeding channel 6, including a first half-shell 11 and a second half-shell 12 that are connected to each other along the dividing surface, and the first half-shell 11 and the second half-shell 12 are detachably and sealingly connected.

[0143] In one embodiment, in an automotive parts assembly line welding scenario, due to the need for frequent equipment maintenance to ensure production efficiency, a convenient split housing 1 structure is adopted. The first half-shell 11 and the second half-shell 12 are horizontally divided along the axis of the wire feeding channel 6, with the dividing surface designed in a stepped shape and two annular grooves at the fitting point. A high-temperature resistant nitrile rubber O-ring is embedded in the groove of the first half-shell 11, and a raised sealing lip is provided at the corresponding position of the second half-shell 12 to ensure a sealing effect. After the two are joined, they are fixed by four sets of press-type buckles distributed around the housing 1. One end of the buckle is hinged to the first half-shell 11, and the other end has a barb structure that can quickly engage with the slot of the second half-shell 12. When the drive wheel 2 wears and needs to be replaced, the operator only needs to press the buckle to unlock it, separating the two half-shells 1 within 10 seconds. After replacing the part, they can be re-fastened, greatly reducing downtime for maintenance and meeting the high-efficiency production requirements of the assembly line.

[0144] This application also proposes that the housing 1 of the booster is hinged to a transparent cover 13, and the booster is provided with a display device and an operation panel 7 located inside the cover. The cover is configured to allow reading of the contents of the display device when closed, and to adjust the operation panel 7 and perform maintenance on the internal components when open.

[0145] In one embodiment, in an automated welding production line for automotive body-in-white, welding conditions need to be frequently switched. The booster housing 1 is made of high-strength engineering plastic, and the hinged transparent cover 13 is made of polycarbonate (PC), which has high light transmittance and impact resistance. Inside the cover, the display device is a color LCD touch screen that displays parameters such as welding voltage, current, and wire feed speed in real time; the voltage and current adjustment knobs and wire feed mode switching buttons on the operation panel 7 are compactly arranged around the display screen.

[0146] When switching welding models on the production line and adjusting parameters is required, operators can clearly view the data on the display device through the closed transparent cover 13 without opening the cover, and quickly modify the parameters via the touch screen. If the equipment experiences an alarm for abnormal wire feeding, the operator can open the cover and directly operate the adjustment knob for fine-tuning. At the same time, they can check whether there is any blockage in the internal drive wheel 2 and the welding wire 8 channel. After completing the maintenance, the cover can be quickly closed to resume production. The entire process is efficient and convenient, effectively reducing production line downtime.

[0147] This application also proposes types of boosters with various power specifications, and each booster has a standardized connector at its input and output ends. The standardized connector includes a coaxially arranged welding wire 8-channel interface, a protective gas channel interface, and an electrical signal transmission interface.

[0148] In one embodiment, the new energy vehicle battery box production line needs to accommodate both aluminum alloy sheet welding and stainless steel frame welding. A low-power booster is used for sheet welding, with standardized connectors compatible with 0.8mm welding wire, quick-connect pneumatic circuits, and high-speed data transmission protocols. When switching to stainless steel frame welding, a high-power booster is directly installed; due to the standardized interface specifications, there is no need for rewiring and piping, enabling rapid equipment switching.

[0149] In one embodiment, the modular booster welding torch is a wire pusher welding torch. The booster is installed on the torch handle near the barrel via a fixed connection. The angle between the straight line containing the welding wire inside the booster and the straight line containing the welding wire inside the torch handle is 15 degrees, falling within the range of 0-30 degrees. From the perspective of motor design, the output shaft direction of the motor forms a matching angle with the extension direction of the torch handle, ensuring that the motor's center of gravity falls near the gripping area of ​​the torch handle. This allows the operator to maintain good balance when holding the torch and prevents increased operational burden due to a shift in the center of gravity.

[0150] In actual welding operations, this angle setting allows for a smooth transition of the welding wire between the booster and the handle, reducing resistance during wire transmission and ensuring wire feeding stability. This improves operational comfort and increases welding efficiency.

[0151] In one embodiment, this modular booster welding gun is a robotic welding gun. The handle of the robotic welding gun does not require manual gripping, but in order to adapt to the installation structure of the robotic arm, the handle is designed with a specific connection interface. Its overall shape is approximately straight, but there is a slight bend at the part connected to the booster. The bending angle is 0 degrees to meet the posture requirements of the robot during operation.

[0152] The booster is mounted on the handle, and the angle between the welding wire inside the booster and the welding wire inside the handle is 0 degrees, at which point the resistance to wire movement is minimized. The motor's design direction has been optimized according to the robot arm's motion trajectory, ensuring that the motor's center of gravity coincides with the overall center of gravity of the robot welding torch. This ensures that the welding torch will not affect welding accuracy due to imbalance during high-speed movement and precise positioning of the robot.

[0153] This angle setting ensures stable wire transmission during the high-speed movement of the robotic welding torch, avoiding wire jitter or jamming caused by excessive angle, and meeting the requirements of high precision and high stability for robotic welding.

[0154] In one embodiment, the modular booster welding torch is a collaborative robot welding torch. Collaborative robot welding torches sometimes require manual adjustment of their posture; therefore, its handle design accommodates both robot installation and manual gripping. The booster is mounted on the handle, with the welding wire inside the booster and the welding wire inside the handle forming a 5-degree angle. The motor's design direction comprehensively considers the characteristics of collaborative operations; its center of gravity position ensures no noticeable imbalance during manual adjustment and maintains balance when the robot moves the welding torch. The 5-degree welding wire angle allows for a wide range of robot movement during collaborative operations while also enabling the operator to clearly observe the welding wire transmission during manual adjustment. This fully demonstrates the adaptability and practicality of the modular booster on different types of welding torches.

[0155] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A modular booster, characterized in that, It includes a drive wheel, a driven wheel and a driver protruding from the housing, wherein the drive wheel is linked to the output shaft of the driver, and the drive wheel and the driven wheel form a wire clamping pair perpendicular to the wire feeding channel axis; The wire feeding channel of the same welding equipment can be connected in series with one or more of the aforementioned boosters to assist in the advancement of the welding wire, according to the actual wire feeding distance requirements. The booster can be installed at a preset angle into the wire feeding channel via a connecting mechanism, the connecting mechanism including a fixed connecting part and / or a rotating connecting part; the booster is fixed to the welding gun handle via the fixed connecting part, and the booster is rotatably connected to the welding cable via the rotating connecting part; The booster, as an independent modular component, is selectively located between the welding torch handle and the welding cable, between two sections of the welding cable, or simultaneously between the two. The wire feeding channel axis of the booster is coaxially connected with the wire feeding channel axis of the adjacent component to form a continuous wire transmission path.

2. The modular booster according to claim 1, characterized in that, The fixed connection part includes: The first connecting member fixed to the housing has an angular positioning feature; The second connector fixed to the welding torch handle has a mating structure adapted to the angular positioning feature.

3. A modular booster according to claim 2, characterized in that, The fixed connection part also includes: The locking element is configured to lock the first connector and the second connector at a preset angle position. The angular positioning feature and mating structure are configured to provide at least one preset angular position, enabling the first connector to be installed onto the second connector at a selected preset angle and held in place by the locking member.

4. A modular booster according to claim 1, characterized in that, The drive wheel's shaft is coaxially arranged with the driver's output shaft. The driver can be configured as a unidirectional wire feeding mode or a pulse-back wire feeding mode. The driver is configured as a servo motor to achieve the pulse-back wire feeding mode.

5. A modular booster according to claim 4, characterized in that, The servo motor of the booster is connected to the controller of the welding machine via a cable.

6. The modular booster according to claim 1 further includes a pressure regulator, the pressure regulator comprising a pressure seat hinged to the housing and an adjustment seat fixed to the housing; The driven wheel is mounted to the pressure seat, and the adjusting seat can change the position of the pressure seat so that the driven wheel moves toward or away from the driving wheel.

7. A modular booster according to claim 1, characterized in that, The rotating connection part includes: A third connecting member fixed to the housing has a rotating interface; A fourth connector fixed to the welding cable has a mating interface adapted to the rotating interface. The adjustment component is configured to adjust the coupling degree between the third connector and the fourth connector to change the rotational resistance between them; The rotating interface and the mating interface are configured to allow the booster to rotate in multiple directions relative to the welding cable. The adjustment component achieves coordinated adjustment of the resistance in each rotation direction by changing the normal force or contact characteristics between the rotating interfaces.

8. A modular booster welding torch, characterized in that, The welding torch includes the booster described in any one of claims 1-6, and the welding torch includes a wire pusher welding torch, a robotic welding torch, and a collaborative robotic welding torch.

9. A modular booster welding torch according to claim 8, wherein the angle between the straight line containing the welding wire in the booster and the straight line containing the welding wire in the welding torch handle is 0-30 degrees.

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