Dual-Contact Welding Torch for Preheated Wire Starts
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Solution Overview
Problem
Current welding techniques lack a method to ensure the electrode is heated prior to initiating welding operations, affecting the consistency and efficiency of the welding process, particularly in cold electrode starts.
Innovation Solution
A liquid-cooled welding torch with a power and liquid transfer assembly that conducts preheating current to the electrode, allowing for resistive heating of the electrode wire before forming a welding arc, while maintaining the same tool center point distance and torch neck angle as conventional torches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cold electrode start is used in welding operations, then the welding process can be initiated without preheating equipment, but the welding performance and consistency are compromised
Solution Approach 1:
The patent applies preliminary action by incorporating a preheating contact tip that heats the electrode wire before welding begins. This preheating action occurs in advance of the main welding process, ensuring the electrode is at the optimal temperature for consistent welding performance without requiring external preheating equipment.
Solution Approach 2:
The contact tip is segmented into two distinct functional parts: a preheating contact tip and a welding contact tip. The preheating contact tip delivers current to heat the electrode, while the welding contact tip delivers current for the actual welding arc. This segmentation allows each tip to be optimized for its specific function, improving overall welding consistency.
2Reliability
If a preheating contact tip is added to the welding torch, then electrode preheating is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the preheating and welding contact tips into a single integrated contact tip assembly that attaches to the welding torch in one piece. This merging approach consolidates multiple functions into a single component, reducing the overall device complexity compared to having separate preheating and welding torches or multiple detachable components.
Solution Approach 2:
The contact tip assembly serves multiple functions: it acts as both a preheating contact tip and a welding contact tip. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall device structure while maintaining the benefits of electrode preheating.
3Device complexity
If the contact tip is designed to accept both preheating and welding currents, then the torch design is simplified, but the contact tip geometry becomes more complex
Solution Approach 1:
The contact tip is designed with local quality variations: the preheating contact tip has a larger diameter and different surface characteristics optimized for delivering preheating current, while the welding contact tip has a smaller diameter and geometry optimized for arc initiation. Each local region of the contact tip assembly has properties tailored to its specific function, resolving the geometric complexity issue through functional specialization.
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 preheating the electrode wire, reducing the risk of collisions and requiring minimal reprogramming of robotic systems.
Implementation Method 1
a liquid cooling assembly configured to deliver the cooling liquid to the welding assembly
Implementation Method 2
Electrical power is applied to the welding wire and a circuit is completed through the workpiece to sustain a welding arc
Data Source
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AI summary
The present application relates to welding torches (1500). A 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 (1500) provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch (1500) having a single contact tip.