Contact Tip Regeneration with Circular Core and Low-Force Reforming
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Solution Overview
Problem
Existing contact tip reforming devices require high operational force and have a short maintenance cycle due to the hexagonal core metal deformation, leading to increased costs and instability in welding quality.
Innovation Solution
A contact tip reforming device with a plastic processing hole featuring projecting portions and recessed surface portions that deform the contact tip without the need for high force, maintaining a circular core metal shape to prevent wear and prolong maintenance cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hexagonal core metal is used to reform the contact tip guide hole, then the welding wire contact stability is improved, but the core metal undergoes angular deformation and wear leading to frequent maintenance
Solution Approach 1:
The patent changes the core metal cross-section from hexagonal to circular shape. The circular core metal eliminates angular parts that are prone to deformation and wear, thereby extending the maintenance cycle while still achieving the desired guide hole shape through plastic deformation of the contact tip material between the circular core and die surfaces.
2Manufacturing precision
If the collet holder divisional parts press the contact tip head end to eliminate slits during reforming, then the guide hole shape is improved, but a large force is required increasing device complexity
Solution Approach 1:
The circular cross-section of the core metal provides a more favorable stress distribution during plastic deformation compared to hexagonal geometry. This reduces the peak forces required to achieve the desired guide hole shape, allowing for simpler device design with lower capability requirements.
3Manufacturing precision
If the core metal cross section conforms to the guide hole shape, then the guide hole reforming precision is improved, but the core metal cannot be pulled out from the guide hole causing device stopping
Solution Approach 1:
The circular core metal maintains a consistent diameter throughout its length, creating a uniform interference fit with the guide hole. This uniform geometry, combined with the plastic deformation of the contact tip material, allows the core to be inserted and removed without getting stuck, ensuring continuous device operation.
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 solution reduces the force required for deformation, stabilizes welding quality by maintaining a polygonal guide hole shape, and extends the maintenance cycle by preventing angular deformation of the core metal, thus lowering costs and improving operational efficiency.
Implementation Method 1
the projecting portions plastically deform the head end side of the contact tip by, when the contact tip is inserted into the plastic processing hole by the approach of the first and second dies to each other by the processing machine, pressing the head end side of the contact tip toward the hole center line until it is in contact with the core metal
Implementation Method 2
a pressing machine that causes the first and second dies to approach each other and separate from each other
Data Source
Figure 1
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AI summary
A device (1) is provided with a first die (2), a second die (3) and a pressing machine (4). The second die (3) is provided with a plastic processing hole (3a) where a core metal (3f) is disposed on a hole center line (C1). On the inner peripheral surface of the plastic processing hole (3a), three projecting portions (3b) are provided at regular intervals in the circumferential direction of the hole center line (C1). By the approach of the first and second dies to each other, the core metal (3f) is inserted into a guide hole (10a) of a contact tip (10), and the projecting portions (3b) plastically deform the head end side of the contact tip (10) by pressing it until it is in contact with the core metal (3f).