Conical Elastic Welding Torch Teaching Tool for Damage-Free Teaching
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Solution Overview
Problem
In robotic welding, especially for large workpieces, it is difficult for operators to teach a weld due to limited visibility from the welding nozzle, making it hard to judge the electrode's position and distance from the workpiece, which can lead to damage to the workpiece or welding torch components.
Innovation Solution
A teaching tool for a welding torch with a non-melting electrode, specifically a plasma welding torch, featuring a connector formed by a truncated cone for tool-free fastening into the gas nozzle, made of elastic material to prevent damage and ensure easy mounting and dismounting, and optionally enhanced with graphitic carbon for increased wear resistance and fluorescent particles for improved visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a normal welding torch with non-melting electrode is used for teaching, then the welding path can be taught, but there is a risk of damaging the workpiece or welding torch components due to poor visibility
Solution Approach 1:
The patent uses a teaching tool that is a simplified copy of the actual welding torch, lacking the expensive and fragile non-melting electrode and gas nozzle. This copy allows operators to practice teaching welding paths without risking damage to the real torch components or workpiece, while maintaining the same basic geometry for accurate path transfer.
Solution Approach 2:
The teaching tool is designed as an inexpensive, disposable alternative to the real welding torch. Made from simple materials like plastic or aluminum with basic geometric features, it can be easily replaced if damaged during teaching operations, eliminating the risk to expensive equipment while providing sufficient functionality for path teaching.
2Ease of operation
If special welding torches with dummy contact tips are used for teaching, then visibility is improved, but the design becomes complex and mounting/dismounting becomes time-consuming
Solution Approach 1:
The teaching tool is designed as a separate, standalone component that can be independently mounted to the torch handle or holder. This segmentation allows the teaching tool to be easily attached and removed without affecting the main welding torch assembly, simplifying both the design and the mounting/dismounting process compared to integrated dummy tips.
Solution Approach 2:
The teaching tool is designed with universal mounting features that can be adapted to different welding torch types. By using standard geometric features and mounting interfaces, it serves multiple functions (teaching, storage, transport) and can be used with various torch configurations, reducing overall system complexity.
3Ease of operation
If the teaching tool uses elastic material with truncated cone connector, then tool-free fastening is achieved, but the friction holding mechanism must be precisely dimensioned
Solution Approach 1:
The teaching tool uses elastic material properties (such as rubber or silicone) that allow the rigid truncated cone dimensions to be slightly less precise. The elastic deformation compensates for dimensional variations, maintaining reliable friction holding without requiring extremely tight manufacturing tolerances on the connector geometry.
Solution Approach 2:
The teaching tool combines the truncated cone connector (for geometric fit) with elastic material (for friction holding) to create a composite mounting system. This combination allows the rigid geometric features to provide alignment and positioning while the elastic material provides the necessary friction and compliance, reducing overall manufacturing precision requirements.
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
The teaching tool allows for simple, safe, and damage-free teaching of welding paths by providing secure, tool-free attachment to the welding torch, minimizing the risk of workpiece or torch component damage, and enhancing visibility in dark environments.
Implementation Method 1
the body (2) is formed of an elastic material
Implementation Method 2
The elastic material of the teaching tool and the corresponding dimensioning allow the teaching tool to be held in the gas nozzle by friction
Implementation Method 3
the connector (4) is formed by a truncated cone (5)
Implementation Method 4
optionally enhanced with graphitic carbon for increased wear resistance
Implementation Method 5
fluorescent particles for improved visibility
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a teaching tool (1) for a welding torch (10) with a gas nozzle (11) with an opening (12) for a non-melting electrode (13) with a tip (14), especially a plasma welding torch (15), used in case of teaching a welding path (X) along a work- piece (W) of the welding torch (10) attached to a welding robot (16), comprising a substantially circularly symmetric body (2) having a free end (3), a welding torch (10) with such a teaching tool (1) and a method for teaching a welding path (X) of a welding torch (10) with such a teaching tool (1), wherein the body (2) is formed of an elastic material. The teaching tool (1) is characterized in that the body (2) comprises a connector (4) arranged opposite the free end (3), which connector (4) is formed by a truncated cone (5) for tool-free fastening in the opening (12) of the gas nozzle (11) of the welding torch (10).