Dual-Contact Welding Torch for Electrode Wire Preheating
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Solution Overview
Problem
Current welding techniques lack a reliable method to ensure the electrode is heated prior to the initiation of a welding operation, affecting the consistency and efficiency of the welding process.
Innovation Solution
A liquid-cooled welding torch with a power and liquid transfer assembly that conducts preheating current and provides cooling liquid to the welding assembly, allowing for resistive preheating of the electrode wire, ensuring it is heated before forming a welding arc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding techniques are used without preheating, then the welding process is simpler, but welding performance and consistency deteriorate
Solution Approach 1:
The patent applies preliminary action by implementing a preheating system that heats the electrode wire before welding begins. The preheating assembly includes heating elements positioned to warm the wire as it feeds through the torch, ensuring the electrode reaches an optimal temperature range prior to arc initiation. This preliminary thermal preparation improves welding performance consistency and reduces defects associated with cold electrode starts.
2Ease of operation
If electrode preheating is implemented, then welding arc initiation is improved, but energy consumption increases
Solution Approach 1:
The patent applies parameter changes by implementing a controllable preheating system that adjusts temperature and heating duration based on welding conditions. The system includes sensors and control circuitry that monitor electrode temperature and modify heating parameters accordingly, optimizing the balance between arc initiation ease and energy consumption for different material types and welding currents.
Solution Approach 2:
The patent applies continuity of useful action by integrating the preheating function into the existing wire feed mechanism. As the electrode wire continuously feeds through the torch, it passes through the heating zone throughout the welding process, ensuring consistent temperature maintenance without requiring separate heating cycles or additional energy-intensive intermittent heating operations.
3Productivity
If liquid cooling assembly is added to the torch, then wire preheating capability is improved, but torch complexity increases
Solution Approach 1:
The patent applies merging by combining multiple functions into integrated assemblies. The liquid cooling assembly is merged with the preheating system, where cooling channels are positioned to surround heating elements. This allows simultaneous wire preheating and torch component cooling through a single integrated structure, improving deposition rate while minimizing the increase in overall torch complexity compared to separate systems.
Solution Approach 2:
The patent applies universality by designing the liquid cooling assembly to serve multiple functions: cooling the torch body, cooling the contact tip, and facilitating wire preheating through the surrounding cooling channels. This multi-functional design allows a single assembly to handle thermal management tasks that would otherwise require separate components, thereby improving productivity with minimal complexity increase.
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 enables improved welding starts and higher deposition rates by consistently preheating the electrode wire, reducing the risk of welding arc energy requirements and maintaining the same tool center point distance and torch neck angle as conventional torches.
Implementation Method 1
A liquid-cooled welding torch with a power and liquid transfer assembly that conducts preheating current and provides cooling liquid to the welding assembly, allowing for resistive preheating of the electrode wire
Implementation Method 2
A liquid-cooled welding torch with a power and liquid transfer assembly that conducts preheating current and provides cooling liquid to the welding assembly
Data Source
AI summary
Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.