Welding Torch Contact Tip Rotary Lock for Tool-Free Replacement

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Solution Overview

Problem

Existing welding systems require tools for replacing and securing contact tips, which complicates maintenance and automation processes.

Innovation Solution

A method and system for securing a contact tip in a welding system without tools, involving the application of an axial force and rotation of the contact tip within a diffuser assembly to align locking elements with a locking mechanism, allowing secure alignment and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a traditional contact tip securement mechanism is used, then the contact tip can be securely held in place, but tools are required for replacement and securement which complicates maintenance and automation processes

Engineering Contradiction:

Improvetool-free replacement and securement of contact tipVSAvoidlocking mechanism complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The contact tip locking mechanism is designed to be self-servicing through a simple rotary motion that engages locking elements with corresponding features on the diffuser assembly. The operator simply rotates the contact tip holder body, and the locking elements automatically engage with the diffuser assembly features, eliminating the need for external tools or complex multi-step securement procedures.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The locking mechanism is divided into discrete locking elements positioned around the periphery of the contact tip holder body, each capable of independent engagement with corresponding features on the diffuser assembly. This segmentation allows for simple rotational engagement while maintaining secure holding capability, resolving the contradiction between ease of operation and securement reliability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a simple contact tip holder design is used, then maintenance is easier, but the contact tip may not be securely held in place during welding operations

Engineering Contradiction:

Improvesecurement of contact tip during weldingVSAvoidlocking mechanism structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking elements and corresponding features on the diffuser assembly are designed with asymmetric geometries that provide directional locking. The locking elements have specific engagement surfaces that mate with corresponding asymmetric features on the diffuser assembly, ensuring reliable securement in the welding direction while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The locking elements are pre-positioned on the contact tip holder body during manufacturing, and the rotary engagement mechanism is designed to automatically align these pre-positioned elements with the diffuser assembly features upon rotation. This preliminary positioning ensures reliable securement without requiring complex adjustment mechanisms during operation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12285827B2Contact tip rotary lock of a welding torch

Publication Date: 2025.04.29 ILLINOIS TOOL WORKS INC

AI summary

A welding torch system includes a diffuser assembly that includes a locking mechanism to receive a contact tip. Additionally, the welding torch system includes the contact tip, which includes locking elements configured to interact with the locking mechanism of the diffuser assembly to secure the contact tip within the diffuser assembly. Further, the contact tip is rotated within the diffuser assembly to securely align the locking elements with the locking mechanism.