Dual-Contact Welding Torch With Liquid Cooling for Electrode Preheating

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Solution Overview

Problem

Current welding techniques lack a regime 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 first contact tip for conducting welding current and a second contact tip for preheating current, along with liquid cooling assemblies, is designed to preheat the electrode wire before forming a welding arc, allowing for consistent and efficient welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single contact tip is used to supply welding current, then the device complexity is reduced, but the welding process consistency and electrode preheating capability deteriorate

Engineering Contradiction:

Improvecontact tip configurationVSAvoidwelding process consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The single contact tip is segmented into two separate contact tips: a first contact tip for supplying welding current and a second contact tip for supplying preheating current. This segmentation allows independent control of welding and preheating functions, improving welding process consistency while maintaining manageable device complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The welding torch is designed with multi-functionality by incorporating both welding current supply and preheating current supply capabilities within a single torch body. The liquid cooling assembly serves dual purposes of cooling both contact tips, and the torch structure accommodates multiple electrical connections, enabling one device to perform multiple functions without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If electrode preheating is added to the welding torch, then the welding start quality and deposition rate improve, but the device complexity increases

Engineering Contradiction:

Improvedeposition rateVSAvoidtorch structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The preheating function is merged with the existing welding torch structure rather than being implemented as a separate device. The liquid cooling assembly, which would normally only cool the welding contact tip, is extended to also cool the preheating contact tip. Electrical connections are merged into a unified system that handles both welding and preheating currents, reducing overall system complexity while enabling preheating functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The welding torch is designed as a multi-functional device that simultaneously provides welding current supply, preheating current supply, and liquid cooling for both contact tips. This universal design allows the single torch to perform multiple functions (welding and preheating) without requiring separate equipment, thereby improving productivity while controlling device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If liquid cooling assemblies are extended to cool both contact tips, then the thermal management effectiveness improves, but the manufacturing complexity increases

Engineering Contradiction:

Improvecontact tip temperature controlVSAvoidtorch assembly

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The liquid cooling channels for the preheating contact tip are nested within or alongside the existing cooling structure for the welding contact tip. The cooling system is designed with a hierarchical structure where the preheating tip cooling passages are integrated into the broader torch cooling architecture, allowing efficient thermal management of both tips while simplifying manufacturing through a unified cooling manifold design.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 preheating of the electrode wire improves welding starts and deposition rates, reducing the risk of collisions and requiring minimal reprogramming of robotic systems, while maintaining the same tool center point distance and torch neck angle as conventional torches.

Implementation Method 1

a first liquid cooling assembly configured to conduct the welding current; and a second liquid cooling assembly configured to conduct the preheating current

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

conduct the preheating current to preheat the consumable electrode

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

liquid cooling assemblies configured to conduct the welding current and the preheating current

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3634685B1Welding torch, with two contact tips and a plurality of liquid cooling assemblies for conducting current to the contact tips

Publication Date: 2022.04.06 ILLINOIS TOOL WORKS INC

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AI summary

The present application relates to a welding torch (200), which includes a first contact tip configured to conduct welding current to a consumable electrode (114), a second contact tip configured to conduct preheating current to the consumable electrode (114), and a plurality of liquid cooling assemblies (208, 210) configured to conduct the preheating current and to conduct the welding current to the consumable electrode (114).