A gas shielded welding apparatus
By using a flow counter and a gas-saving valve in the gas-shielded welding device, the gas flow rate is precisely controlled, solving the problems of gas waste and emissions, and achieving the effects of saving gas usage and reducing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI ZHENHUA HEAVY IND
- Filing Date
- 2025-06-17
- Publication Date
- 2026-06-26
AI Technical Summary
In existing carbon dioxide gas shielded welding processes, the gas flow is unstable and waste is significant, especially outdoors or in windy environments, resulting in high carbon emissions and high costs.
A gas-shielded welding device is used, including a gas flow counter and a gas-saving valve, which reduces gas consumption and emissions by precisely controlling the gas flow.
This method significantly reduces gas flow and emissions while ensuring welding quality, thereby lowering costs and saving gas usage.
Smart Images
Figure CN224406617U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of gas shielded welding equipment, and in particular to a gas shielded welding device. Background Technology
[0002] Carbon dioxide gas shielded welding is a gas shielded arc welding method widely used in various fields, such as marine engineering equipment manufacturing and port machinery manufacturing. During the welding process, the welding wire is continuously fed through a wire feeder. Under the action of the welding power source, an electric arc is generated between the welding wire and the workpiece. The high temperature of the arc causes the welding wire and the workpiece to locally melt, forming a molten pool. As the arc moves, the molten pool cools and solidifies to form the weld. During the welding process, carbon dioxide gas is used as a shielding gas to isolate the welding area from air, preventing harmful effects from oxygen, nitrogen, and other gases in the air on the molten pool.
[0003] Traditional CO2 gas shielded welding of thick plates typically uses a CO2 gas flow rate of 20L / min to 25L / min. When welding outdoors or in windy environments, the gas flow rate needs to be increased appropriately to prevent the shielding gas from being blown away. Furthermore, the CO2 gas output from the welding torch is extremely turbulent and unstable during the initial start-up phase. Therefore, a period of venting is required before commencing welding to stabilize the CO2 gas flow rate.
[0004] This process consumes and releases a large amount of carbon dioxide gas, resulting in carbon waste. Therefore, efficient and cost-effective welding gas-saving technology is crucial to reducing carbon emissions during welding. Existing intelligent welding gas-saving devices can adjust the welding gas flow rate in real time based on the welding current by setting the evaluation sampling number of the welding current through the control system. However, these devices are relatively cumbersome to operate, and the overall cost is too high. Utility Model Content
[0005] The purpose of this invention is at least to provide a gas-shielded welding device that can reduce the flow rate of the shielding gas required for gas-shielded welding, thereby reducing the amount of gas emitted.
[0006] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.
[0007] One embodiment of this utility model provides a gas shielded welding device, which includes a welding machine body, a gas flow counter, and a throttle valve; the first end of the gas flow counter is connected to the gas inlet, the second end of the gas flow counter is connected to the first end of the throttle valve, and the second end of the throttle valve is connected to the gas outlet; the throttle valve is used to control the gas flow, the throttle valve is installed on the welding machine body, and the gas outlet is located on the welding machine body.
[0008] In some embodiments, the flow rate range of the gas flow counter is less than 20 L / min.
[0009] In some embodiments, the flow rate range of the gas flow counter is less than 15 L / min.
[0010] In some embodiments, the flow rate range of the gas flow counter is less than 12 L / min.
[0011] In some embodiments, the gas shielded welding apparatus includes a gas regulator, and the first end of the gas flow counter is connected to the gas inlet through the gas regulator, wherein the gas regulator is used to regulate the gas pressure at the gas inlet and the gas outlet.
[0012] In some embodiments, the gas flow counter includes a Hall sensor, which is used to convert changes in the magnetic field caused by the gas into an electrical signal.
[0013] In some embodiments, the gas-shielded welding apparatus includes a gas supply pipe or gas cylinder for supplying carbon dioxide gas to the gas inlet.
[0014] In some embodiments, the gas-shielded welding apparatus includes a gas heating unit for heating carbon dioxide gas in a gas supply pipeline or gas cylinder.
[0015] In some embodiments, the gas-shielded welding apparatus includes a gas supply pipeline, and an air inlet, a gas flow counter, and a throttle valve are connected in sequence through the gas supply pipeline.
[0016] In some embodiments, the welding machine body includes a wire feeding assembly and a welding torch, the wire feeding assembly being used to feed welding wire to the welding torch, and an air outlet being disposed on the welding torch.
[0017] The gas shielded welding device of this utility model includes a throttle valve and a gas flow counter. The throttle valve controls the gas flow rate, and the gas flow counter monitors the gas flow rate. The throttle valve is adjusted according to the gas flow rate data of the gas flow counter, which can reduce the shielding gas flow rate required for gas shielded welding and reduce the gas emission. By simplifying the arrangement of components in the gas shielded welding device, the overall cost is reduced. Attached Figure Description
[0018] The above-described features and advantages of this invention can be better understood after reading the following detailed description of the embodiments of this disclosure in conjunction with the accompanying drawings. In the drawings, the components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals. Wherein:
[0019] Figure 1 This is a connection block diagram of a gas-shielded welding apparatus according to some embodiments;
[0020] Figure 2 This is a connection diagram of a gas-shielded welding apparatus according to some embodiments.
[0021] Explanation of reference numerals in the attached figures:
[0022] 100-Gas shielded welding equipment;
[0023] 110 - Gas Flow Counter;
[0024] 111-Hall sensor;
[0025] 120 - Throttle valve;
[0026] 130 - Welding machine body;
[0027] 140 - Gas Regulator;
[0028] 150-gas cylinder;
[0029] 160 - Gas heating unit. Detailed Implementation
[0030] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.
[0031] It should be understood that the terms “system,” “device,” “unit,” and / or “module” used herein are one method of distinguishing different components, elements, parts, sections, or assemblies at different levels. However, if other words can achieve the same purpose, they may be replaced by other expressions.
[0032] It is understood that the technical terms that may be involved in the description of this specification, such as “center,” “longitudinal,” “lateral,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the implementation method and do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of the utility model.
[0033] It should be noted that the use of terms such as "first" and "second" to define features in this document is merely for the purpose of distinguishing the corresponding features. Unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this utility model. As shown in this specification and claims, the terms "a," "an," "a kind," and / or "the" do not specifically refer to the singular and may also include the plural, unless the context clearly indicates otherwise. Generally, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, and these steps and elements do not constitute an exclusive list; the method or apparatus may also include other steps or elements.
[0034] In the description of this specification, it should also be noted that, unless otherwise expressly specified or limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this specification according to the specific circumstances.
[0035] Figure 1 This is a connection block diagram of a gas-shielded welding apparatus according to some embodiments.
[0036] This specification provides an embodiment of a gas-shielded welding apparatus 100, such as... Figure 1 As shown, the gas shielded welding device 100 includes a gas flow counter 110, a throttle valve 120, and a welding machine body 130.
[0037] Gas flow counter 110 is used to monitor gas flow. The first end of gas flow counter 110 is connected to the air inlet for air intake. The second end of gas flow counter 110 is connected to the first end of throttle valve 120, and the second end of throttle valve 120 is connected to the air outlet.
[0038] The throttle valve 120 is used to control the gas flow rate. By adjusting the throttle valve 120, the gas flow rate output from the outlet can be regulated. In some embodiments, the throttle valve 120 is installed on the welding machine body 130 for easy adjustment. The outlet is located on the welding machine body 130 and is used to output gas.
[0039] In some embodiments, the welding machine body 130 includes a wire feeding assembly and a welding torch. The wire feeding assembly feeds welding wire to the welding torch, and a gas outlet is disposed on the welding torch. Under the action of the welding power source, an electric arc is generated between the welding wire and the workpiece. The high temperature of the arc causes the welding wire and the workpiece to partially melt and form a molten pool. The gas outlet is disposed on the welding torch so that the gas output from the gas outlet, such as carbon dioxide gas, serves as a protective gas for welding, isolating the air from contact with the molten pool and preventing oxygen, nitrogen, and other gases in the air from having a harmful effect on the molten pool.
[0040] The term "connection" as used in this specification refers to connection via a gas supply pipeline. In some embodiments, the gas-shielded welding apparatus 100 includes a gas supply pipeline, and an inlet, a gas flow counter 110, a throttle valve 120, and an outlet are sequentially connected via the gas supply pipeline.
[0041] In some embodiments, by adjusting the throttle valve 120, the flow rate monitored by the gas flow counter 110 is made less than 20 L / min. Existing gas shielded welding typically uses gas flow rates of 20 L / min to 25 L / min or greater than 25 L / min. The gas shielded welding apparatus 100 described in this specification simplifies the arrangement of components on the gas supply pipeline, reduces the pipeline length, and achieves precise control of the gas flow rate through the throttle valve 120, making the flow rate monitored by the gas flow counter 110 less than 20 L / min. This reduces gas usage, lowers the required gas flow rate, reduces gas emissions, and simultaneously ensures the effectiveness of the shielded welding.
[0042] In some embodiments, by adjusting the throttle valve 120, the flow rate monitored by the gas flow counter 110 is made less than 15 L / min. In some embodiments, by adjusting the throttle valve 120, the flow rate monitored by the gas flow counter 110 is made less than 12 L / min. Using the gas shielded welding apparatus 100 described in this specification, by adjusting the throttle valve 120 and using a carbon dioxide gas flow rate of less than 12 L / min for shielded welding, diffused hydrogen test blocks, welding qualification test pieces, deposited metal test pieces, small iron grinding test pieces, etc., were welded. The subsequent test results of each test piece were basically consistent with the welding effect using existing high gas flow rates, and no major defects were found. The gas shielded welding apparatus 100 can reduce the carbon dioxide gas flow rate required for shielded welding, significantly reducing carbon dioxide emissions. Moreover, the components are simplified, reducing the initial budget investment and achieving the goal of cost reduction and efficiency improvement.
[0043] Taking the butt weld flat weld test of A709-50-2 steel plate as an example, this illustrates how the gas-shielded welding device 100 effectively protects the weld while using a small flow rate of shielding gas. Specifically:
[0044] In the butt welding test of flux-cored wire, the thickness of the specimen is 20 mm, the width of a single specimen is not less than 100 mm, and the length should be sufficient to provide for cutting specimens of the specified size and quantity, as well as to ensure the size and quantity of samples for arbitration in case of disputes. The edges of the two specimens are set at a 30° bevel, and the root assembly gap is 2-3 mm to achieve butt welding.
[0045] Welding is performed using a method of 2-3 passes per layer, for a total of 7-9 layers. The welding direction of each pass should change at the edge of the specimen. After each pass, remove the slag and place the specimen in still air to allow the weld to cool to below 250°C, but not necessarily below 100°C (the weld temperature is measured on the upper surface at a distance of 75mm from the weld center) before welding the next pass. After all butt weld specimens have been welded on one side, clean the weld root (using carbon gouging) until defect-free metal is exposed before proceeding with the back side welding.
[0046] During the butt welding test, the gas flow data was recorded by the gas flow counter 110 after each weld was completed. After all welds were completed, the gas flow data were summarized and compared.
[0047] Data comparison shows that using existing gas shielded welding equipment with a carbon dioxide gas flow rate of 20 L / min and using gas shielded welding equipment 100 with a carbon dioxide gas flow rate of 12 L / min, the welding results are consistent. However, comparing the gas flow rate data of welding a set of test pieces using the existing gas shielded welding equipment and using gas shielded welding equipment 100, the gas saving of gas shielded welding equipment 100 is 388 L, and the gas saving efficiency is 53%.
[0048] Figure 2 This is a connection diagram of a gas-shielded welding apparatus according to some embodiments.
[0049] In some embodiments, the gas shielded welding apparatus 100 includes a gas supply pipe or gas cylinder for supplying a shielding gas for welding—carbon dioxide gas—to the gas inlet. Figure 2 A gas cylinder 150 is shown, which is connected to an inlet and supplies carbon dioxide gas to the inlet and the gas supply pipeline. In some embodiments, to prevent condensation of the carbon dioxide gas in the gas cylinder or gas supply pipeline, the gas shielded welding apparatus 100 includes a gas heating unit 160 for heating the carbon dioxide gas in the gas supply pipeline or gas cylinder. For example, the gas heating unit is an electric heating component that uses the heat from a resistance wire to heat the carbon dioxide gas in the gas supply pipeline or gas cylinder.
[0050] In some embodiments, such as Figure 2As shown, the gas shielded welding device 100 includes a gas regulator 140. The first end of the gas flow counter 110 is connected to the gas inlet through the gas regulator 140. The gas regulator 140 is used to regulate the gas pressure at the gas inlet and the gas outlet, so that the carbon dioxide gas in the gas cylinder or gas supply pipeline can smoothly enter the gas supply pipeline through the gas inlet. By regulating the gas pressure through the gas regulator 140, the pressure of the gas output from the gas outlet can enable the carbon dioxide gas to complete the protection of the molten pool.
[0051] In some embodiments, the gas flow counter 110 includes a Hall sensor 111. The gas flowing through the gas flow counter 110 can cause a change in the magnetic field of the Hall sensor 111. The Hall sensor 111 converts this change in magnetic field into an electrical signal, thereby enabling the gas flow counter 110 to monitor the flow rate of the gas.
[0052] The basic concepts have been described above. It is clear that the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification, especially for those skilled in the art. Furthermore, unless expressly stated in the claims, the order of elements and sequences, the use of numbers and letters, or other names in this specification are not intended to limit the order of the processes and methods described herein. Although various examples of utility model embodiments that are currently considered useful have been discussed in the foregoing disclosure, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. Rather, the claims are intended to cover all modifications and equivalent combinations that conform to the substance and scope of the embodiments described herein.
Claims
1. A gas-shielded welding apparatus, characterized in that, The gas-shielded welding device includes a welding machine body, a gas flow counter, and a gas throttle valve; The first end of the gas flow counter is connected to the air inlet, the second end of the gas flow counter is connected to the first end of the throttle valve, and the second end of the throttle valve is connected to the air outlet. The throttle valve is used to control the gas flow rate. The throttle valve is installed on the welding machine body, and the gas outlet is located on the welding machine body.
2. The gas-shielded welding apparatus according to claim 1, characterized in that, The flow rate range of the gas flow counter is less than 20 L / min.
3. The gas-shielded welding apparatus according to claim 1, characterized in that, The flow rate range of the gas flow counter is less than 15 L / min.
4. The gas-shielded welding apparatus according to claim 1, characterized in that, The flow rate range of the gas flow counter is less than 12 L / min.
5. The gas-shielded welding apparatus according to claim 1, characterized in that, The gas-shielded welding device includes a gas regulator, and the first end of the gas flow counter is connected to the air inlet through the gas regulator. The gas regulator is used to adjust the gas pressure at the air inlet and the air outlet.
6. The gas-shielded welding apparatus according to claim 1 or 5, characterized in that, The gas flow counter includes a Hall sensor, which is used to convert changes in the magnetic field caused by the gas into an electrical signal.
7. The gas-shielded welding apparatus according to claim 1 or 5, characterized in that, The gas-shielded welding device includes a gas supply pipe or a gas cylinder, which is used to supply carbon dioxide gas to the gas inlet.
8. The gas-shielded welding apparatus according to claim 7, characterized in that, The gas-shielded welding device includes a gas heating unit, which is used to heat carbon dioxide gas in the gas supply pipeline or the gas cylinder.
9. The gas-shielded welding apparatus according to claim 1 or 5, characterized in that, The gas-shielded welding device includes a gas supply pipeline, and the gas inlet, the gas flow counter, and the throttle valve are connected in sequence through the gas supply pipeline.
10. The gas-shielded welding apparatus according to claim 1, characterized in that, The welding machine body includes a wire feeding assembly and a welding torch. The wire feeding assembly is used to feed welding wire to the welding torch, and the air outlet is provided on the welding torch.