Continuous cooling welding head

Abstract

This disclosure describes a system comprising a support structure configured to provide support for various automated welding components. The system also comprises an automated welding head body mounted on the support structure. The automated welding head body is manufactured from a thermally conductive material and includes at least one cooling bar extending at least a portion of the length of the automated welding head body. The cooling bar includes various internal cooling passages that define the path of coolant through the cooling bar of the automated welding head body. The automated welding head body also includes at least one pressurized fluid input line that is coupled to the internal cooling passage of the cooling bar and directs a fluid coolant into the internal cooling passage of the cooling bar. Other apparatus and automated welding machines are also described.

Description

Description of Related Applications

[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 486,863, filed Feb. 24, 2023, which is hereby incorporated by reference in its entirety.

Technical Field

[0002] This disclosure relates to continuous cooling type welding heads.

Background Art

[0003] Orbital welding is a fusion welding process that uses gas tungsten arc welding (GTAW) technology in a unique way when joining structural pipes and tubular materials. GTAW is often considered the cleanest and most widely used process in high reliability and high performance welding. Orbital welding, along with sequential programming, implements a control device, an inverter power source, a servo motor, and gears, and can rotate a welding head (usually tungsten) around a workpiece with high consistency. Orbital welding can precisely control an electric arc that can melt a small amount of material at a very high temperature, thereby accurately fusing the target area of the workpiece, targeting and joining the molten material, and forming a uniform and mechanically stable weld joint precisely through a homogeneous process.

[0004] In particular, the GTAW orbital welding process does not require filler metals or fluxes. Rather, this process joins the base materials of joints and tubular products to each other under an inert gas environment or “shield”. Different from other processes that use filler metals or fluxes, when the base materials of a weld joint are melted homogeneously, usually, a weld with higher reliability can be obtained due to its essential cleanliness. This is because, in addition to the absence of filler metals and fluxes, the inert gas functions as a shield for the molten metal, significantly reducing potential air pollution and undesirable molecular characteristics.

[0005] Furthermore, automated welding does not require an "open flame" and produces fewer contaminants. This automated welding process provides superior welded joints and eliminates the potential hazards frequently seen in open-flame processes, which can cause fires, damage to surrounding structures and workers, as well as welding spatter, arc flash, and harmful fumes. Automated welding is a "closed arc" process in which the welding head used for the work surrounds the workpiece from all sides, and an inert gas completely envelops the welding area. This protects the welding zone from oxidation and contamination, while also protecting workers from the dangerous arc flash and intense heat that can occur during the process. [Overview of the Initiative]

[0006] This disclosure relates, in general, to a continuous-cooled automatic welding head capable of operating at much higher heat and much higher currents than conventional welding solutions. In fact, in some cases, the continuous-cooled automatic welding heads described herein can operate at welding currents two to four times higher than standard welding industry currents. For example, in some cases, the continuous-cooled automatic welding heads described herein can be practiced to weld copper pipes to copper fittings at a range of 125 to 200 amperes, which would destroy a conventional welding machine in the first few welds.

[0007] As mentioned earlier, conventional welding heads have been developed for industries welding materials such as stainless steel alloys, titanium, Hastelloy, Inconel, or other metals. These metals are typically welded at amperages ranging from 40 to 120 amperes. However, these metals are insufficient for some newly emerging applications. For example, some welding applications use constituent materials with high melting temperatures or high conductivity. In such cases, the molten pad necessary to form a stable weld cannot be produced without applying a significantly high current to the work surface (for example, in the case of copper welding).

[0008] In welding applications requiring high currents to maintain weld integrity, such currents generate significantly large amounts of heat, potentially degrading the internal mechanisms of the welding head and causing serious damage. These welding heads cannot withstand welding at such high currents, even in repetitive operations of any kind. In fact, these welding heads cannot withstand the heat generated by high currents, the mechanical properties of the constituent materials are compromised, and expensive repairs become necessary. To maintain productivity in these new welding applications, different constituent materials should be adopted.

[0009] In more specific cases, the constituent materials used in existing welding head designs are primarily composed of insulating materials, with the "body" or "housing" being the main component of the welding head, intended to protect the rotor, gears, electrical and control wiring, and cooling system (e.g., hoses and cooling blocks) from conductive heat and potential arc strikes during operation. These insulating materials typically function very well when welding with currents of approximately 35–125 amperes. Currents exceeding this range will cause the current design to overheat, leading to degradation and / or damage of these welding heads in a very short period of time (e.g., 1–5 welds).

[0010] In contrast to conventional insulating materials used in conventional welding heads, embodiments of this specification construct an automated welding head with multiple fluid channels that enable high flow rates of coolant to the welding head body, using the body as a large heat sink. Conventional designs use a small "cooling block" within the insulating body and cannot withstand repeated welding at high currents (e.g., 125 amperes or more), but embodiments described herein have been demonstrated to withstand extreme heat. Highly conductive materials are employed in the manufacture of the cooled welding head, presenting supercritical cooling of the welding head body. These materials include aluminum, copper, and other conductive metals. These metals form the body of the welding head, providing cooling speeds and performance that far exceed those of conventional welding machines. Embodiments of this specification provide a robust and durable welding head that can repeatedly perform high-current welding in high-production, high-power environments.

[0011] In some cases, the structure of the welding head body may consist of various conductive materials and can be manufactured using metal 3D printing, investment casting, or complex machining operations. This allows the flow of the fluid coolant to reach a large surface area, which can be composed of conductive material. As a result, the heat generated by the application of high currents can be safely and effectively transferred to the cooling system, thereby allowing the recirculating coolant to be cooled before being returned to the welding head using pumps, heat exchangers, and / or cooling fans. This heat-conductive welding head and cooling system can transfer heat at a rate that existing insulating welding heads are never designed to withstand due to their (intentionally) low thermal conductivity and heat transfer capacity.

[0012] Embodiments of supercritical cooling welding heads described herein may include at least some of the following: 1) a rotor designed to have an insulating shield; 2) a thermally conductive material for the body of the automatic welding head. The conductive material applied as the body of the welding head dissipates heat from the internal structure of the welding head, allowing the welding head to operate at very high temperatures for extended periods; 3) cooling passages that provide a high surface area inside the body of the welding head. This allows the cooling system to flow the coolant at a higher flow rate, enabling the body of the welding head to function as a large heat sink rather than just an insulator; 4) a tool that allows a detachable cassette to be secured to the body of the welding head using a cam lock or other fastening mechanism and to be quickly removed.

[0013] Before providing further details of this disclosure, it should be understood that this disclosure is not limited to the specific parameters of the systems, apparatus, assemblies, products, devices, kits, methods, and / or processes particularly illustrated, and that these may naturally vary. It should also be understood that many, if not all, of the technical terms used herein are solely for the purpose of describing specific embodiments of this disclosure and are not necessarily intended to limit the scope of this disclosure in any particular way. Therefore, while this disclosure is described in detail with reference to specific configurations, embodiments, and / or embodiments thereof, such descriptions are illustrative and should not be construed as limiting the scope of the inventions described in the claims.

[0014] Various aspects of this disclosure, including devices, systems, methods, etc., may be described with reference to one or more exemplary embodiments or manifestations. As used herein, the terms “exemplary embodiments” and / or “exemplary manifestations” mean “to serve as examples, cases, or illustrations” and should not necessarily be construed as preferred or advantageous to other embodiments or manifestations disclosed herein. Furthermore, references to “manifestations” of this disclosure or the invention include specific references to one or more embodiments thereof, and vice versa, and are intended to provide illustrative examples without limiting the scope of the invention as shown by the accompanying claims rather than by the following description.

[0015] Furthermore, unless otherwise specified, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art in the field to which this disclosure relates. Numerous methods, materials, components, etc., similar or equivalent to those described herein may be used in the practice of this disclosure, but only specific illustrative methods, materials, components, etc. are described herein.

[0016] It should be noted that, as used herein and in the accompanying claims, nouns include multiple referents unless the context clearly indicates otherwise. Therefore, for example, a reference to “column” may include one, two, or more columns. Similarly, a reference to multiple referents should be interpreted as including a singular and / or multiple referents unless the content and / or context clearly indicates otherwise. Therefore, a reference to “column” does not necessarily require multiple such columns. Instead, regardless of morphological variations, it will be recognized herein that one or more columns are possible.

[0017] As used throughout this application, the words “can” and “may” are used in an impermissible sense (i.e., meaning to have the possibility of doing something) rather than an impermissible sense (i.e., meaning to have the possibility of doing something). In addition, the terms “including,” “having,” “involving,” “containing,” “characterized by,” and their variations (e.g., “includes,” “has,” “involves,” “contains,” etc.), and similar terms used herein, including in the claims, are inclusive and / or open and have the same meaning as the word “comprising” and its variations (e.g., “comprise” and “comprises”), and do not exemplify any additional unlisted elements or steps of the method.

[0018] Various aspects of this disclosure can be described by describing components that are coupled, attached, connected, and / or joined to one another. The terms “coupled,” “attached,” “connected,” and / or “joined,” as used herein, are used to indicate either a direct relationship between two components or, where appropriate, an indirect relationship to one another through an intervening or intermediate component. In contrast, where components are referred to as “directly coupled,” “directly attached,” “directly connected,” and / or “directly joined,” there is neither an intervening element nor any conceivable intervening element.

[0019] Therefore, as used here, terms such as “connected” and “joined” do not necessarily imply direct contact between two or more elements. In addition, interconnected, attached, connected, and / or joined components are not necessarily fixed to each other (reversibly or permanently). For example, interconnection, attachment, connection, and / or joining may, in some embodiment, involve arranging, positioning, and / or placing multiple components one another or adjacent to each other.

[0020] Terms indicating direction, such as “top,” “bottom,” “front,” “back,” “forward,” “rear,” “left,” “right,” “up,” “down,” “top,” “bottom,” “inside,” “outside,” “internal,” “external,” “inside,” “outside,” “forward,” “rear,” “proximal,” and “distal,” as used herein, and / or any other terms, may be used solely for convenience and / or to indicate relative direction and / or orientation, and are not intended to limit the scope of this disclosure, including the specification, invention, and / or claims. Accordingly, such terms indicating direction and / or any other terms should not be construed as necessarily requiring a particular order or position.

[0021] To facilitate understanding, similar reference numbers are used wherever possible to specify similar elements common to the drawings. Furthermore, each of the alternative configurations of a particular element may include a distinct letter appended to the element number. Thus, the appended letter can be used to specify a design, structure, function, embodiment, and / or embodiment in place of an element or feature without the appended letter. Similarly, each of the multiple cases of elements and / or sub-elements of a parent element may include a distinct letter appended to the element number.

[0022] In each case, element labels may be used without adjectives to broadly refer to the element or any one of its alternative elements. Element labels with adjectives may be used to refer to a particular case of the element or to distinguish or draw attention to multiple uses of the element. However, element labels with adjectives are not intended to be limited to the specific embodiments and / or special embodiments in which they are described. In other words, references to certain features relating to an embodiment should not be interpreted as being limited to use only within that embodiment.

[0023] Where two or more values ​​or ranges of values ​​(e.g., less than, greater than, at least, and / or up to a specific value, and / or between two enumerated values) are disclosed or enumerated, it will be recognized that any specific values ​​or ranges of values ​​that fall within the disclosed values ​​or ranges of values ​​are also disclosed and conceivable herein. Therefore, disclosures of measurements or distances useful in describing about 10 units or less or between 0 and 10 units include, as an example, specific disclosures of (i) measurements of any other values ​​between 0 and 10 units, including 9 units, 5 units, 1 unit, or 0 and / or 10 units; and / or (ii) measurements of any other ranges of values ​​between 9 and 1 unit, between 8 and 2 units, between 6 and 4 units, and / or between 0 and 10 units.

[0024] In the described embodiments, various modifications can be made without departing from the spirit and scope of the invention defined in the claims. Therefore, although various aspects and embodiments are disclosed herein, other aspects and embodiments are also conceivable. Also, it should be noted that a system, apparatus, assembly, product, device, kit, method, and / or process according to a particular embodiment of the present disclosure can include, incorporate, or otherwise be configured with the characteristics, features, components, members, and / or elements described in other embodiments disclosed and / or described herein. Therefore, references to specific characteristics related to a particular embodiment should not be construed as being limited only to their application within that embodiment. The headings used herein are for purposes of organization only and are not intended to be used to limit the scope of the description or claims.

Brief Description of the Drawings

[0025] The accompanying drawings show a number of exemplary embodiments and are part of the specification. These drawings, together with the following description, demonstrate and explain various principles of the present disclosure. [Figure 1A] Perspective view of an embodiment of an automatic welding system or an automatic welder [Figure 1B] Side view of an embodiment of an automatic welding system or an automatic welder [Figure 2] Exploded perspective view of an embodiment of an automatic welding removable cassette [Figure 3] Exploded perspective view of an embodiment of an automatic welding head body [Figure 4] Exploded perspective view of an embodiment of an automatic welding head [Figure 5] Top view of an embodiment of an automatic welding system or an automatic welder including a welding head body and a welding head [Figure 6A] Diagram showing an embodiment of an automatic welding head body having a cooling passage [Figure 6B] Diagram showing an embodiment of an automatic welding head body having a cooling passage [Figure 6C]A diagram showing an embodiment of an automatic welding head body having a cooling passage. [Modes for carrying out the invention]

[0026] Throughout the drawings, the same reference letters and descriptions indicate elements that are similar but not necessarily identical. While the exemplary embodiments described herein are subject to various modifications and alternative forms, certain embodiments are shown as examples in the drawings and described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to any particular form disclosed. Rather, this disclosure encompasses all modifications, equivalents, and alternatives that fall within the scope of this disclosure.

[0027] Moving on to the drawings, Figure 1A shows an embodiment of System 100. System 100 may have more or fewer components than those shown in Figures 1A and 1B. For example, System 100 may include electrical wiring, pressurized fluid piping, inert gas piping, and other input lines that help power the system or operate the system mechanically. In some cases, System 100 may be an automatic welding system or automatic welding machine, specifically a high-current, continuously cooled automatic welding machine. In contrast to conventional automatic welding machines or systems that implement adiabatic welding head bodies and operate at amperages of less than 125 amperes, the embodiments described herein implement conductive welding head bodies that are continuously cooled using a pressurized fluid coolant. This allows System 100 to operate at amperages greater than 125 amperes, and as a result, can weld materials (e.g., copper pipes and copper fittings) that could not be welded at all or with any level of consistency or quality previously.

[0028] The system 100 in Figure 1A is fitted to and surrounded by a coupling 101 that includes various input lines, including power input lines, fluid input lines, gas input lines (e.g., for inert gases), or other input lines. The system 100 also includes a support structure 102, some of which may function as handles. Handles, which may be part of the support structure 102, are used to hold and control the automatic welding system when operating around a weld piece. The support structure 102 may also include other subframes or support members that provide structural support and rigidity to the automatic welding system. The support structure 102 may provide fittings, screw holes, clips, or other fastening or fixing mechanisms to direct various electrical, mechanical, and fluid elements or other automatic welding components of the automatic welding system.

[0029] Furthermore, the system 100 also includes an automatic welding head body 103 mounted on a support structure 102. The automatic welding head body 103 may be manufactured entirely or at least partially from a thermally conductive material (e.g., copper, gold, silver, etc.). The automatic welding head body may include at least one cooling bar (e.g., 304A in Figure 3) extending at least a portion of the length of the automatic welding head body 103. This cooling bar may include one or more internal cooling passages (e.g., 507A / 705B in Figure 5) for passing coolant through the cooling bar of the automatic welding head body 103. The automatic welding head body 103 may also include at least one pressurized fluid input line (e.g., 603 in Figure 6) coupled to the internal cooling passage of the cooling bar, leading a fluid coolant into the internal cooling passage of the cooling bar. Many of these individual components are not shown in Figure 1A, but these components are shown in more detail in Figures 3-6C.

[0030] As shown in Figures 1A and 1B, the automatic welding head body 103 may be part of a detachable cassette 110. The detachable cassette 110 can be removed from the support structure 102 using a locking handle 106 and / or a locking pin. In some cases, a part of the detachable cassette itself may be hinged (e.g., via hinge 111) and detached from the cassette body using a locking pin 107. By removing it in this way, the hinged portion 105 swings downward, allowing a pipe and / or fitting to be inserted into the opening 104 for automatic welding. Once the weld piece is inserted, the hinged portion 105 can be closed and locked in place using the locking pin 107. The internal welding head can then be rotated around the weld piece to weld the pieces together. The detachable cassette 110 is illustrated with respect to Figure 2 and is described in more detail below.

[0031] Figure 2 shows an embodiment of a detachable cassette 200 having multiple components. For example, the detachable cassette 200 may have an upper part 201 and a lower part 204. The welding head and cooling bars (generally shown in Figures 3 and 4) may be located inside the upper and lower parts of the detachable cassette 200. The detachable cassette 200 has an opening 202 for passing through a portion of a pipe and / or fittings. In some cases, the detachable cassette 200 may have one or more cooling bars, each having its own cooling passage. These cooling bars and passages may be added to any other cooling bars (e.g., in the welding head body). The cooling bars and passages within the detachable cassette 200 may have their own pressurized fluid input lines to supply fluid coolant to the cooling bars of the cassette. In such cases, the outer part of the detachable cassette 200 may enclose and protect the cooling bars and cooling passages. The upper and lower parts of the detachable cassette 200 are fastened together and can be securely held in place by clips 202 or other fastening mechanisms.

[0032] In some cases, by releasing the clips, the hinged removable parts 203 / 205 of the detachable cassette 200 can be opened and made accessible through the opening 202. For example, when in the open position, fittings and pipe sections can be placed within the opening 202. Fittings and pipe sections may be manufactured from copper, aluminum, stainless steel, or substantially any other weldable non-ferrous material. The hinged removable parts 203 / 205 can then be closed to enclose the fittings and pipe sections. In some cases, each of the hinged removable parts 203 and 205 may be opened separately, and each may have separate clips to secure its respective removable part to the top and bottom. The welding head and welding head body are housed in a cavity created by the upper part 201 and lower part 204 of the detachable cassette 200. The welding head and welding head body are described in more detail below with respect to Figure 3.

[0033] Figure 3 shows an exploded view of embodiment 300 of the welding head body, welding head, and associated components. As previously mentioned, the welding head and welding head body can reside within a cavity created by the detachable cassette 200 of Figure 2. The detachable cassette 200 can itself be attached to the end of the automatic welding system. Embodiment 300 includes a cooling bar 304A extending at least a portion of the length of the automatic welding head body 309. The cooling bar 304A includes various internal cooling passages (not visible in Figure 3) for passing coolant through the cooling bar of the automatic welding head body 309. In some cases, the welding head body includes a second different cooling bar 304B extending across the opposite portion of the length of the automatic welding head body 309.

[0034] The cooling bars 304A and 304B may be covered and held in place by protective plates 303 and 306 that connect to the top and bottom of the cooling bars. The cooling bars and protective plates 303 / 306 may be held in place by themselves by a rotary fastening mechanism 301 that connects to a latch mechanism 307 via a rod 305 that penetrates the welding head body 309 between structural elements 302 and 308. As previously mentioned, the cooling bars may be made of conductive material. In some cases, the protective plates 303 and / or 306 may be made of conductive material. In contrast to conventional systems in which the welding head body is insulated, the welding head body in Figure 3 may be designed to conduct heat. This conductive heat is then dissipated through cooling passages in the cooling bars 304A / 304B. This active liquid cooling allows the welding head (not shown in Figure 3) to operate at very high temperatures resulting from unusually high current amounts. In fact, the embodiments described herein can be repeatedly and reliably operated at 2 to 4 times the conventional amperage used in automated welding (e.g., 125 to 200 amperes or more).

[0035] The cooling bars 304A / 304B can generally surround the internal welding head components and the welding head, as shown in Figure 4. Figure 4 shows an exploded view of embodiment 400 of the welding head 414 and associated components. The welding head 414 may include a number of component pieces, including an outer protective layer 405, an insulating layer 406, conductive layers 407 and 409 separated by spacers 408, a second insulating layer 411, a gear layer 412 that rotates the welding head around an axis, and an outer protective layer 413. The welding head 414 may include an arc 410 made of tungsten or other material. The welding head 414 may be connected to structural support components 401, 402, 403, and 404. These structural support components can hold the welding head 414 in place within the welding head body (for example, in the cavity between the cooling bars 304A and 304B). These structural support components can conduct electricity to the conductive layers 407 and 409 of the welding head 414, and can also transmit rotational force (provided by a motor) to the gear layer 412, thereby rotating the teeth of the gear layer.

[0036] The insulating layers 406 and 411 allow the welding head 414 to withstand repeated operation using very high currents without melting or exploding. The insulating layers may be made of ceramic or other thermal dielectric insulating material, while the conductive layer may be made of copper or another conductor. The welding head 414 can operate for long durations while receiving unusually high currents (e.g., 125 amperes or more). Since the welding head body is thermally conductive and actively cooled, and the welding head 414 includes insulating layers to prevent arc discharge to structural components or other layers of the welding head, the embodiments described herein can reliably and repeatedly weld at current levels not possible with conventional automatic welding machines.

[0037] Figure 5 shows a top view of an embodiment of the automatic welding machine or system 500. In this embodiment, the upper protective plate is removed so that the lower component 505 is visible. The automatic welding system 500 includes an input port 501 through which power, pressurized fluid, electrical grounding, or other electrical or mechanical input can be supplied to the automatic welding system 500. The automatic welding system 500 may further include a support structure 502, at least a portion of which can function as a handle for the user during the automatic welding process.

[0038] Furthermore, in at least some embodiments, the automatic welding system 500 includes a fluid diverter 503. The fluid diverter 503 may include a single input and two or more fluid outputs 504. In some cases, hoses may extend from the input port 501 to the diverter 503 and from the fluid outputs 504 to the internal cooling passages 507A and 507B of the cooling bars 508A and 508B. Each of the internal cooling passages 507A / 507B may include an input port 506A / 506B and an output port 509A / 509B. In such cases, the cooling fluid can flow into the input port 506A / 506B, circulate through the respective cooling passages 507A / 507B, and reach the output ports 509A / 509B. The fluid heated while moving through the internal cooling passages 507A / 507B can then exit the automatic welding system 500 and be cooled by an external heat pump or other cooling mechanism.

[0039] As previously mentioned, the welding head 510 can operate at very high amperages. These high amperages generate a large amount of heat. In contrast to conventional systems that implement an insulated welding head body, the embodiments described herein implement a thermally conductive welding head body and, specifically, a cooling bar 508A / 508B which is a part of the welding head body. The thermally conductive cooling bar 508A / 508B is thermally conductive, so as to dissipate at least some of the heat from the automatic welding head 510 and any weld piece. In addition, the cooling bar 508A / 508B also includes an internal cooling passage 507A / 507B through which a pressurized fluid flows into the cooling bar. This pressurized coolant continuously draws heated coolant from the system and continuously delivers fresh, cold fluid into the internal cooling passage 507A / 507B of the cooling bar. This process significantly reduces the heat of the welding head body and its internal components, allowing the welding head 510 to perform accurate and stable automatic welding repeatedly for many hours.

[0040] Figures 6A-6C illustrate embodiments of the automatic welding system 600 in more detail. In Figure 6A, for example, internal cooling passages 606 and 607 can be seen rising on one side of each cooling bar 609 and 610 and descending on the opposite side of each cooling bar. The cooling bars 609 / 610 can at least partially enclose the automatic welding head 608. As previously mentioned, the automatic welding head body, including the cooling bars 609 / 610 and the automatic welding head 608, can be fixed to the support structure 602 using a number of different fastening mechanisms (e.g., screws, clips, or other fasteners). In the embodiment of Figure 6A, power is supplied to the automatic welding head 608 through the power input line 605. Similarly, pressurized cooling fluid is supplied or fed into the internal cooling passages 606 and 607 through the fluid input line 603. Other inputs, such as inert gas, can also be supplied through the input port 601.

[0041] In some cases, the fluid input line reaches a diverter, where the fluid is directed to each of the two cooling bars 609 and 610. While many of the embodiments described herein implement two cooling bars, it should be noted that substantially any number of cooling bars may be used. In fact, in some embodiments, a single cooling bar may be used, while in other cases, multiple cooling bars may be stacked on top of each other or positioned at different locations around the automatic welding head 608. Furthermore, although the cooling bars 609 / 610 are generally shown as a "C-shaped" curve, the cooling bars 609 / 610 may be formed into substantially any shape, including circular, square, triangular, rectangular, "horseshoe," irregular shapes, or several other shapes. The internal cooling passages 606 and 607 may be formed correspondingly to the contours of the cooling bars 609 / 610 in such cases.

[0042] Furthermore, substantially any number of internal cooling passages may be used. In some cases, for example, the cooling bar may be 3 units high (e.g., mm, cm, etc.), with the first cooling passage located at 1 unit and the second cooling passage at 2 units. Alternatively, the cooling bar may be 5 units thick and have cooling passages located at 1, 2, 3, and 4 units. Thus, in such cases, multiple cooling passages may be arranged above each other, separated by a certain distance. In these embodiments, each internal cooling passage may have its own pressurized fluid input and output lines, or some or all passages may share fluid input and output lines. Thus, it will be recognized that many variations in the size, shape, number, and arrangement of the cooling bar and internal cooling passages can be realized within an automatic welding machine or system.

[0043] Figure 6A includes a dotted circle 6B, the contents of which are shown in more detail in Figure 6B. Figure 6B shows the power input line 605 and the fluid input line 603. The power input line 605 can supply power to the automatic welding head, while the fluid input line 603 can supply coolant to the internal cooling passage 606. The internal cooling passage 606 may have input and return lines that run through part or all of the length of the cooling bar 609. Other input lines, including an inert gas input line 604, may also be implemented in the automatic welding system.

[0044] Figure 6C shows a single cooling bar 609 having an input port 612, an output port 613, and a cooling passage 606. The cooling passage may extend along the outer edge of the cooling bar 609 and may follow the shape and size of the cooling bar. In some cases, the cooling bar 609 may include openings 611 for connecting to other components, including protective plates that can cover the cooling bar. In such cases, the cooling passage 606 may extend around or between those openings. In some cases, the width of the cooling passage 606 may be uniform or vary over the range of the cooling bar. A hotter width can accommodate more coolant, while a narrower width allows for more maneuverability or flexibility when designing the flow of the internal cooling passage 606.

[0045] In some cases, the thermal conductivity of the automatic welding head body may be specially designed or manufactured to have or exceed at least a minimum thermal conductivity threshold. Such an automatic welding head body may be designed to automatically weld copper pieces using, for example, at least 100 amperes without damaging the automatic welding head. As shown in Figure 6A, the automatic welding head positioned between two cooling bars 609 and 610 may be insulated to withstand an unusually large amount of current. By using a thermally conductive welding head body in combination with cooling bars having internal cooling passages and an insulated automatic welding head, the embodiments described herein enable automatic welding of materials that would not have been possible using previous equipment, or that would have caused the welding head to melt and become unusable, and / or the welding head body to melt.

[0046] In addition to the systems described above, an automatic welding machine may be provided comprising a support structure designed to provide support for one or more automatic welding components and an automatic welding head body attached to the support structure. The automatic welding head body comprises a thermally conductive material. The automatic welding head body comprises at least one cooling bar extending at least a portion of the length of the automatic welding head body, the cooling bar including one or more internal cooling passages for flowing a coolant into the cooling bar of the automatic welding head body, and at least one pressurized fluid input line attached to the internal cooling passage of the cooling bar for guiding a fluid coolant into the internal cooling passage of the cooling bar.

[0047] In addition, or instead, an apparatus may be provided comprising a support structure designed to provide support for one or more automatic welding components and an automatic welding head body mounted on the support structure. The automatic welding head body comprises a thermally conductive material. The automatic welding head body comprises at least one cooling bar extending at least a portion of the length of the automatic welding head body, the cooling bar including one or more internal cooling passages for flowing a coolant into the cooling bar of the automatic welding head body, and at least one pressurized fluid input line attached to the internal cooling passage of the cooling bar for guiding a fluid coolant into the internal cooling passage of the cooling bar.

[0048] The above description is provided so that those skilled in the art can make the most of the various aspects of the exemplary embodiments disclosed herein. This exemplary description is not intended to be exhaustive or to limit to any exact form disclosed. Many modifications and variations are possible without departing from the spirit and scope of this disclosure. The embodiments disclosed herein should be considered in all respects to be exemplary and not limiting. In determining the scope of this disclosure, refer to the appended claims and their equivalents.

[0049] Unless otherwise specified, the terms “connected” and “linked” (and their derivatives) as used in the specification and / or claims should be interpreted to acknowledge both direct and indirect (i.e., through other elements or components) connections. In addition, “a” and “an” as used in the specification and / or claims should be interpreted to mean “at least one of.” Finally, for ease of use, the terms “including” and “having” (and their derivatives) as used in the specification and / or claims are interchangeable with the word “comprising” and have the same meaning. [Explanation of Symbols]

[0050] 100 Systems 101 Fittings 102, 502 Support structure 103 Automatic welding head body 104, 202 aperture 105 Hinge section 106 Lock Handle 107 Locking pins 110, 200 Detachable Cassette 111 Hinge 201 Top 203, 205 Removable parts 204 Lower 301 Rotary fastening mechanism 303, 306 Protective plate 304A, 304B, 508A, 508B, 609, 610 Cooling Bar 305 Rod 307 Latch mechanism 309 Automatic welding head body 401, 402, 403, 404 Structural support components 406, 411 Insulating layer 407, 409 Conduction layer 408 Spacer 410 Arc 412 Gear Layer 414, 510, 608 welding heads 500, 600 Automatic Welding Systems 503 Fluid Diverter 506A, 506B, 601, 612 input ports 507A, 507B, 606, 607 Internal cooling passages 509A, 509B, 613 output ports 603 Fluid input line 605 Power input line

Claims

1. A support structure designed to provide support for one or more automatic welding components, and An automatic welding head body made of a thermally conductive material, attached to the aforementioned support structure, A cooling bar comprising at least one cooling bar extending at least a portion of the length of the automatic welding head body, the cooling bar including one or more internal cooling passages for flowing a coolant to the cooling bar of the automatic welding head body, At least one pressurized fluid input line is attached to the internal cooling passage of the cooling bar and guides a fluid coolant into the internal cooling passage of the cooling bar, Automatic welding head body including A system equipped with this feature.

2. The system according to claim 1, wherein the internal cooling passage rises on the first side of the cooling bar and descends on the opposite second side of the cooling bar.

3. The system according to claim 1, further comprising a detachable cassette that is detachably connected to the support structure.

4. The system according to claim 3, wherein the detachable cassette includes an automatic welding head designed to automatically weld two or more material pieces together.

5. The system according to claim 4, wherein the two or more material pieces to be automatically welded together are formed of copper.

6. The aforementioned automatic welding head body A second cooling bar extending over at least a portion of the length of the automatic welding head body, the second cooling bar including one or more internal cooling passages for flowing a coolant to the second cooling bar of the automatic welding head body, and A second pressurized fluid input line is attached to the internal cooling passage of the second cooling bar and guides a fluid coolant into the internal cooling passage of the second cooling bar. The system according to claim 1, further comprising:

7. The system according to claim 6, further comprising a fluid diverter connected to the pressurized fluid input line and the second pressurized fluid input line, wherein the fluid diverter provides the fluid coolant to both the internal cooling passage of the cooling bar and the internal cooling passage of the second cooling bar.

8. The system according to claim 6, wherein the cooling bar and the second cooling bar are fixed to the support structure by a plurality of different fastening mechanisms.

9. The system according to claim 6, wherein an automatic welding head is positioned between the cooling bar and the second cooling bar.

10. The system according to claim 9, wherein the automatic welding head, the cooling bar, and the second cooling bar are covered with a structural plate.

11. The system according to claim 9, wherein the automatic welding head includes at least one insulating layer formed from a thermal insulation material.

12. The system according to claim 1, wherein the thermal conductivity of the automatic welding head body exceeds a minimum thermal conductivity threshold.

13. A support structure designed to provide support for one or more automatic welding components, and An automatic welding head body made of a thermally conductive material, attached to the aforementioned support structure, A cooling bar comprising at least one cooling bar extending at least a portion of the length of the automatic welding head body, the cooling bar including one or more internal cooling passages for flowing a coolant to the cooling bar of the automatic welding head body, At least one pressurized fluid input line is attached to the internal cooling passage of the cooling bar and guides a fluid coolant into the internal cooling passage of the cooling bar, Automatic welding head body including An automatic welding machine equipped with [a specific feature].

14. The aforementioned automatic welding head body A second cooling bar extending over at least a portion of the length of the automatic welding head body, the second cooling bar including one or more internal cooling passages for flowing a coolant to the second cooling bar of the automatic welding head body, and A second pressurized fluid input line is attached to the internal cooling passage of the second cooling bar and guides a fluid coolant into the internal cooling passage of the second cooling bar. The automatic welding machine according to claim 13, further comprising:

15. The automatic welding machine according to claim 14, further comprising an automatic welding head positioned between the cooling bar and the second cooling bar.

16. The automatic welding machine according to claim 15, wherein the automatic welding head is configured to automatically weld copper using at least 100 amperes.

17. The automatic welding machine according to claim 14, wherein both the cooling bar and the second cooling bar are part of a detachable cassette that is detachably attached to the support structure.

18. The automatic welding machine according to claim 14, wherein the automatic welding head, the cooling bar, and the second cooling bar are covered with a structural plate.

19. The automatic welding machine according to claim 14, wherein the automatic welding head includes at least one insulating layer formed from a thermal dielectric insulating material.

20. A support structure designed to provide support for one or more automatic welding components, and An automatic welding head body made of a thermally conductive material, attached to the aforementioned support structure, A cooling bar comprising at least one cooling bar extending at least a portion of the length of the automatic welding head body, the cooling bar including one or more internal cooling passages for flowing a coolant to the cooling bar of the automatic welding head body, At least one pressurized fluid input line is attached to the internal cooling passage of the cooling bar and guides a fluid coolant into the internal cooling passage of the cooling bar, Automatic welding head body including A device equipped with.

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