Coolant Line Retraction Valve for Spill-Free Electrode Replacement
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Solution Overview
Problem
Existing heat exchanger systems for resistance welding machines face challenges in minimizing coolant spillage during electrode replacement, as residual pressurized water can escape, posing hazards and requiring complex mechanical solutions that are prone to maintenance issues and limited effectiveness.
Innovation Solution
A multi-way valve system with a single control valve and optional check valves is used to simultaneously stop coolant flow and divert it through a bypass passageway with a fluid restriction, creating a suction force to evacuate fluid from the coolant lines, thereby minimizing spillage and reducing system complexity and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a piston in a cylinder is used to generate suction force to pull water back from coolant lines, then spillage is reduced to some degree, but the system is subject to maintenance issues because water contacts the piston and cylinder, and the effectiveness is limited by the fixed stroke of the piston
Solution Approach 1:
The patent replaces the mechanical piston-cylinder suction system with a non-mechanical valve-based flow control system. The suction force is generated by directing coolant flow through a bypass passage with a restriction, creating a pressure differential that draws coolant from the electrode coolant line without mechanical moving parts contacting the water.
Solution Approach 2:
The patent uses hydraulic principles by utilizing the coolant flow itself to generate suction force through a restriction in the bypass passage. The flowing coolant creates a pressure differential that actively draws residual coolant from the electrode line, replacing mechanical suction with fluid dynamics.
2Reliability
If multiple valves are used in multiple fluid lines to accomplish evacuation without moving parts, then maintenance issues are eliminated, but device complexity increases
Solution Approach 1:
The patent combines multiple valve functions into a single multi-way valve that can selectively direct coolant flow through different passages. This single valve performs both the function of stopping coolant flow to the electrode and directing flow through the bypass passage, eliminating the need for multiple separate valves while reducing component count.
Solution Approach 2:
The multi-way valve serves multiple functions: it controls coolant flow to the electrode, directs flow through the bypass passage to generate suction, and can isolate different portions of the system. This universal component replaces what would otherwise require multiple specialized valves.
3Ease of operation
If shutdown of coolant flow is achieved by simple valve closure, then operation is simple, but residual pressurized water remains in the isolated section and causes spillage
Solution Approach 1:
The patent performs preliminary action by actively removing residual coolant from the electrode coolant line before the electrode is fully disconnected. The suction force generated by the bypass flow draws out trapped coolant, preventing spillage that would occur with simple valve closure alone.
Solution Approach 2:
The patent converts the harmful effect of residual pressurized water into a beneficial evacuation process. By using the coolant flow itself to generate suction through a restriction, the system actively pulls residual water from the isolated section, turning potential spillage into controlled evacuation.
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 solution ensures consistent and simultaneous fluid control and evacuation, reducing part count, system costs, and failure modes, while preventing leakage and ensuring safety during electrode replacement and maintenance.
Implementation Method 1
The bypass passageway creates a suction force from a sufficient circulation flow of the liquid coolant through a fluid restriction disposed in the bypass passageway
Implementation Method 2
at least one section of the bypass passageway has at least one fluid restriction coupled to a gradually changing cross-sectional area on either side
Data Source
AI summary
System, method, and apparatus for controlling circulation of fluid to, and evacuation of the fluid from, an external fluid circuit for heat transfer. A single control valve selectively stops the circulation of fluid from a supply passageway to an external fluid circuit, and diverts fluid to a bypass passageway which creates a suction force at a fluid restriction therein. A suction passageway couples the suction force of bypass passageway to either return passageway or supply passageway, for evacuating fluid from external fluid circuit. No other valve is disposed or required in the supply passageway or the bypass passageway apart from the single control valve. No more than a single actuator is required to operate the apparatus. No more than a single suction passageway is required to be coupled to either supply passageway and/or return passageway. A return check valve disposed in return passageway prevents backflow of fluid through return passageway.