Welding Electrode Coolant Drawback With Single-Actuator Shutoff
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Solution Overview
Problem
Current cooling systems for resistance welding machines experience substantial liquid spillage when welding electrodes are removed, posing hazards and inefficiencies due to incomplete shutdown of coolant flow.
Innovation Solution
A system utilizing a single actuator to control both liquid shutoff valves and drawback apparatus, which simultaneously stops coolant flow and draws residual liquid away from the electrodes, incorporating mechanical, hydraulic, pneumatic, or electromagnetic coupling, and includes non-return check valves to prevent backflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single actuator is used to control both shutoff valves and drawback apparatus, then device complexity is reduced, but control precision and reliability may be compromised
Solution Approach 1:
The patent combines multiple control functions (shutoff valve control and drawback apparatus control) into a single actuator. This single actuator is mechanically or hydraulically coupled to both the shutoff valves and the drawback apparatus, allowing simultaneous control of multiple components with one actuation event, thereby reducing overall system complexity while maintaining coordinated operation.
Solution Approach 2:
The single actuator serves multiple functions by being coupled to control both the shutoff valves and the drawback apparatus. This multi-functional design allows one component to perform what would traditionally require separate actuators, reducing the number of parts while ensuring that both cooling system functions are controlled together during electrode removal.
2Object-affected harmful factors
If coolant flow is stopped at the source when electrode is removed, then liquid spillage is reduced, but residual coolant remains in the system causing hazards
Solution Approach 1:
The drawback apparatus is activated simultaneously with the shutoff valves through the single actuator. This preliminary action draws residual coolant from the electrode cooling channels before the shutoff valves completely stop the flow, preventing hazardous accumulation of pressurized coolant in the disconnected electrode while the main spillage is already being controlled.
Solution Approach 2:
The drawback apparatus acts as an intermediary mechanism between the coolant supply system and the removed electrode. It actively removes residual coolant from the electrode cooling channels, serving as a bridge that safely transitions the system from a state where coolant is flowing to a state where the electrode is disconnected, preventing both spillage and residual hazards.
3Reliability
If multiple actuators are used for shutoff valves and drawback apparatus, then control precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the control functions of multiple actuators into a single actuator that simultaneously controls both the shutoff valves and the drawback apparatus. This is achieved through mechanical or hydraulic coupling where one actuator's motion is transmitted to multiple control points, reducing component count while maintaining synchronized operation.
Solution Approach 2:
The single actuator is designed with multi-functionality to perform what would traditionally require separate actuators. It is coupled to control both the cooling system shutoff valves and the drawback apparatus, allowing one component to execute multiple control functions that ensure both spillage prevention and residual coolant removal.
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
Effectively reduces or eliminates liquid loss during electrode detachment, maintaining system safety and efficiency in high electrical current environments, and facilitates maintenance by ensuring coolant is drawn back from the cooling system.
Implementation Method 1
the actuator is i) mechanically, ii) hydraulically, iii) pneumatically, or iv) electromagnetically coupled to the one or more liquid shutoff valves and to the one or more liquid drawback apparatus
Implementation Method 2
the actuator is i) mechanically, ii) hydraulically, iii) pneumatically, or iv) electromagnetically coupled to the one or more liquid shutoff valves and to the one or more liquid drawback apparatus
Implementation Method 3
the liquid drawback apparatus includes a non-return check valve, disposed in the fluid passageway and biased against a normal flow of the liquid from the coolant supply
Implementation Method 4
The first drawback element may include at least a piston and a chamber, the piston configured to drawback the liquid coolant away from the gap and into the chamber
Data Source
AI summary
A method, apparatus, and system for stopping a flow of a liquid coolant into, and drawing away a residual portion of the liquid, a portion of a cooling system, e.g., for resistance welding electrodes. The disclosed system does not require more than a single actuator, and in one case uses only a single actuator, coupled to both i) one or more liquid shutoff valves and ii) one or more liquid drawback apparatus. The liquid drawback apparatus draws on the liquid at approximately a same time that the one or more liquid shutoff valves shut off the flow of the liquid from the coolant supply. The liquid drawback apparatus includes a non-return check valve, disposed in the fluid passageway and biased against a normal flow of the liquid from the coolant supply.