Submerged Arc Welding Torch with Dual-Tip Resistive Preheating
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Solution Overview
Problem
Submerged arc welding systems face inefficiencies in preheating electrode wires, as existing technologies often require significant modifications and lack effective methods to reduce arc energy while maintaining welding performance.
Innovation Solution
The development of submerged arc welding torches that provide both preheating and welding current to the electrode wire, utilizing a design with copper mass and an insulator to enable resistive preheating, allowing for retrofit into conventional systems with minimal form factor changes, and using power connectors for separate current paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional submerged arc welding torches are used without resistive preheating, then the system maintains simplicity and compatibility with existing setups, but arc energy requirements remain high and preheating efficiency is insufficient
Solution Approach 1:
The patent combines resistive preheating functionality with the conventional submerged arc welding torch by integrating a preheating contact tip and insulator into the existing torch structure. This merging allows the torch to perform both welding and preheating functions simultaneously without requiring separate preheating equipment, thereby reducing overall system complexity while lowering arc energy requirements.
Solution Approach 2:
The modified torch design enables the welding torch to serve multiple functions: it delivers both welding current and preheating current through separate contact tips. This multi-functionality allows a single device to replace what would traditionally require separate preheating equipment and welding equipment, improving energy efficiency without proportionally increasing complexity.
2Productivity
If resistive preheating is implemented with separate current paths, then preheating efficiency improves and arc energy is reduced, but the torch requires additional components and modified electrical connections
Solution Approach 1:
The torch electrical system is segmented into separate current paths: a welding current path and a preheating current path. Each path has its own contact tip and electrical connection point. This segmentation allows independent control of preheating and welding currents, improving preheating efficiency while keeping the electrical architecture organized and manageable through clear functional separation.
Solution Approach 2:
An insulator is introduced as an intermediary component between the preheating contact tip and the welding contact tip. This insulator prevents electrical interference and short circuits between the two current paths while allowing both contacts to be positioned close to the wire feed. The intermediary enables efficient preheating without compromising electrical safety or increasing connection complexity significantly.
3Reliability
If copper mass is added to the torch for resistive preheating, then the torch can withstand welding parameters and thermal loads, but the form factor and weight of the torch increase
Solution Approach 1:
Copper mass is added locally to specific areas of the torch where thermal management is critical, particularly in the contact tip region and current path components. This localized copper reinforcement provides the necessary thermal conductivity and heat sinking capability to withstand welding parameters without requiring a complete redesign of the entire torch structure, thereby minimizing overall weight increase while maintaining reliability.
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 enables efficient preheating of electrode wires, reducing arc energy requirements and maintaining the durability and performance of conventional submerged arc welding systems, while allowing for cost-effective integration with existing setups.
Implementation Method 1
submerged arc welding torches that provide both preheating and welding current to the electrode wire, utilizing a design with copper mass and an insulator to enable resistive preheating
Data Source
AI summary
Submerged arc welding torches and systems to resistively preheat electrode wire are disclosed. A disclosed example submerged arc welding torch includes: a first contact tip configured to transfer weld current and preheating current to the wire; a second contact tip configured to conduct the preheating current to the wire; an air-cooled first conductive body portion configured to receive the weld current and to conduct the weld current and the preheating current to the first contact tip; an air-cooled second conductive body portion configured to receive the preheating current and to conduct the preheating current to the second contact tip; and an insulator coupled between the first and second conductive body portions.