Concentric Suction Nozzle for Welding Exhaust Control
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Solution Overview
Problem
Existing welding and soldering technologies face challenges in optimizing exhaust gas extraction while maintaining a stable protective gas atmosphere, leading to inefficiencies in shielding gas consumption and weld quality.
Innovation Solution
A method and device that control extraction power and area based on process parameters, such as torch feed speed, wire feed speed, and flue gas composition, using a data processing unit and expert system to adjust suction settings automatically, ensuring precise extraction without disturbing the protective gas cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a suction device is used to extract exhaust gases during welding or soldering in a protective gas atmosphere, then the harmful exhaust gases are removed from the workplace, but the protective gas cover is disturbed and shielding gas is swept away from the welding point
Solution Approach 1:
The suction device is nested within the protective gas nozzle structure, with the suction element positioned concentrically inside the gas outlet. This allows the suction flow to be contained within the protective gas envelope, extracting exhaust gases without allowing external air currents to disturb the protective gas cover at the welding point.
Solution Approach 2:
The suction flow is localized to specific regions where exhaust gases are generated, with the suction element positioned at predetermined locations within the nozzle. This localized extraction removes harmful gases while maintaining the overall protective gas atmosphere, as the suction is concentrated where needed rather than creating general air currents that would disturb the shield.
2Productivity
If the suction flow is increased to improve exhaust gas extraction, then more exhaust gases are removed, but more shielding gas is also sucked away from the welding point
Solution Approach 1:
The system incorporates sensors that detect the concentration of exhaust gases and the stability of the protective gas cover in real-time. This feedback information is used to dynamically adjust the suction flow rate, increasing extraction when exhaust gas levels are high while maintaining minimum levels required to preserve the protective gas atmosphere, thereby optimizing the balance between extraction efficiency and shielding gas consumption.
Solution Approach 2:
The suction flow rate is made dynamically adjustable rather than fixed, allowing the system to adapt to varying welding conditions, material types, and exhaust gas generation rates. This dynamic control enables the suction to be optimized for each specific welding scenario, extracting sufficient exhaust gases while minimizing unnecessary shielding gas loss.
3Object-affected harmful factors
If the suction element is positioned close to the welding point to improve extraction, then exhaust gases are removed more effectively, but the protective gas cover is compromised
Solution Approach 1:
The suction element is nested within the protective gas nozzle structure, positioned concentrically inside the gas outlet at a precise distance from the welding point. This nested positioning allows the suction to operate in the immediate vicinity of the weld where exhaust gases are generated, while the surrounding protective gas flow maintains the shield, ensuring both effective extraction and weld quality.
Solution Approach 2:
The protective gas flow acts as an intermediary between the suction element and the welding point. The suction element extracts exhaust gases through the protective gas envelope without directly contacting the welding point, allowing effective exhaust removal while the protective gas maintains a stable cover over the molten pool, preserving weld quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a clean, high-quality weld or soldered seam with minimized shielding gas consumption, reduced temperature loss, and lower energy consumption, while ensuring reliable extraction of exhaust gases without compromising the protective gas atmosphere.
Implementation Method 1
the suction element (5) of the suction device (2) is surrounded concentrically by the protective gas outlet (20) of the burner (9), wherein the suction element (5) is adjusted depending on parameters of the welding or soldering process
Data Source
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AI summary
Welding or soldering under an inert gas atmosphere by a welding- or a soldering device, comprises exhausting the resulting exhaust gases by at least one suction device, where the suction is controlled depending on the process parameters of the welding- or the soldering process. The process parameters include burner feeding speed, wire feeding speed, wire diameter, wire material, current and/or current-direction, where at least one parameter is determined and evaluated in a data processing unit. An independent claim is also included for a device for the welding or the soldering under an inert gas atmosphere, comprising the suction device for exhausting the resulting exhaust gases, where the suction device exhibits a control unit and a data processing unit. The control unit is coupled with an energy source for the welding- or the soldering process via a data line for the process parameters of the welding- or the soldering process. The data processing unit operates the process parameters.