Detachable Welding Torch Connector for Multi-Process Cable Reuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Welding torch systems with permanently attached cables lead to unnecessary replacement of serviceable components due to damage, resulting in expensive and time-consuming processes, as the entire torch head must be replaced along with the cable.
Innovation Solution
A modular multi-use cable assembly with detachable welding-type torches, allowing for easy swapping and replacement of torches without needing to replace the entire cable, featuring a connector with multiple channels for data, power, signals, and gas transmission, and a secure locking mechanism to ensure stable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torch head is fixed to a cable, then the connection is stable and reliable, but replacement of the cable requires replacement of the torch head as well, increasing cost and time
Solution Approach 1:
The system divides the welding equipment into separable modules: a reusable cable assembly with connector and interchangeable torch heads. Each torch head can be detached and replaced independently without affecting the cable assembly, enabling selective replacement of only the defective component.
Solution Approach 2:
The connector design allows the torch head to transition between fixed and movable states. During operation, the torch head is securely fixed to ensure stable connection, but during maintenance, it can be easily detached and replaced, providing dynamic adaptability between reliability and ease of repair.
2Adaptability or versatility
If a torch head must be replaced, then a replacement cable comes attached to the replacement torch, but this results in unnecessary replacement of serviceable components, increasing cost and time
Solution Approach 1:
The cable assembly and torch head are segmented into separate replaceable units. The cable assembly remains in service while only the torch head is replaced, preventing unnecessary replacement of the serviceable cable component and reducing material waste.
Solution Approach 2:
The cable assembly with its connector is designed as a universal interface that can accommodate multiple torch head types. This allows a single cable assembly to serve multiple functions with different torch heads, reducing the need to replace the entire assembly and minimizing component loss.
3Adaptability or versatility
If multiple welding-type torches are used across multiple weld processes, then the system is versatile, but a separate cable is needed for each torch, increasing complexity and cost
Solution Approach 1:
The cable assembly is designed as a multi-functional universal interface that can connect to various welding-type torches across different weld processes. A single cable assembly replaces the need for multiple dedicated cables, simplifying cable management while maintaining versatility.
Solution Approach 2:
Multiple cable functions are merged into a single cable assembly that can serve multiple torch types. The connector design integrates various connection capabilities into one unified interface, reducing the total number of cables needed and lowering system complexity.
Data Source
AI summary
Aspects of a welding-type cable and torch are provided. The welding-type cable includes a power conductor to conduct welding-type power and a weld torch interface on a distal end of the welding-type cable to attach a weld torch to the power conductor. The welding-type torch includes a power connector to transfer welding-type power between the welding-type torch and a power conductor of a welding-type cable that is detachably coupled to the power connector. An electrode to perform a welding-type operation using the welding-type power is also provided.