External Welding Gun Arc Sensor With Adjustable Annular Motion
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Solution Overview
Problem
Conventional rotating arc sensors have complex structures, large volumes, significant vibrations, and inconvenient maintenance due to the in-built welding gun, limiting their application in high-speed and large-arc welding.
Innovation Solution
A rotating arc sensor design featuring a motor, a connecting rod for annular movement, a sliding assembly for weight support, and an eccentric oscillating member with adjustable flanges, allowing the welding gun to be detachably positioned outside the sensor, ensuring precise movement and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding gun is built in the arc sensor, then the tracking effect is good, but the maintenance and replacement of the welding gun is inconvenient
Solution Approach 1:
The arc sensor is divided into separate functional modules: the sensor body, the connecting rod mechanism, and the welding gun are independent components that can be assembled and disassembled. The welding gun is connected to the sensor through a standardized interface, allowing it to be removed and replaced without affecting the sensor body, thus maintaining tracking precision while enabling easy maintenance.
Solution Approach 2:
The welding gun is extracted from the integrated sensor structure and positioned externally through the connecting rod mechanism. This allows the welding gun to be detached from the sensor body, enabling independent maintenance and replacement of the welding gun while the sensor continues to function for tracking.
2Reliability
If a motor drives the welding gun to perform conical movement, then the tracking effect is good, but the structure is complicated and the volume is large
Solution Approach 1:
Instead of having the motor directly drive the welding gun in a complex conical motion, the design inverts the approach: the motor rotates a first flange, and an eccentrically mounted second flange converts this rotation into the required conical motion of the connecting rod. This inversion simplifies the drive mechanism while achieving the same tracking effect.
Solution Approach 2:
The first flange and second flange act as intermediary elements between the motor and the welding gun. The motor drives the first flange, which through the eccentric connection to the second flange, mediates the motion transformation into conical movement of the connecting rod, simplifying the overall structure.
3Ease of operation
If the welding gun is built in the arc sensor, then the accessibility is good, but the adjustment is inconvenient
Solution Approach 1:
The connection between the welding gun and the sensor is made dynamic and adjustable rather than fixed. The connecting rod mechanism allows the welding gun to be positioned at different angles and positions, and can be easily adjusted or replaced, combining good accessibility during operation with convenient adjustment when needed.
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
Enables convenient maintenance and replacement of the welding gun while maintaining precise movement trajectories, and allows for adjustable annular path diameters to accommodate different welding requirements.
Implementation Method 1
a motor, a connecting rod for driving a welding gun to perform an annular movement
Implementation Method 2
The other end of the connecting rod is connected with the inner wall of the second flange through a bearing assembly
Implementation Method 3
a first assembly for supporting the weight of the connecting rod and supporting a free movement of one end of the connecting rod
Data Source
AI summary
A rotating are sensor is provided. The rotating arc sensor includes a motor, a connecting rod for driving a welding gun to perform an annular movement, a sliding assembly for supporting a weight of the connecting rod and supporting a free movement of a first end of the connecting rod, and an eccentric oscillating member for driving a second end of the connecting rod to perform the annular movement, wherein a center of a rotating shaft of the motor is provided with a hollow cavity capable of communicating with both ends of the motor, the sliding assembly is disposed at a top end of the motor, and the first end of the connecting rod protrudes out of the top end of the motor through the hollow cavity and is connected with the sliding assembly. The eccentric oscillating member includes a first flange and a second flange.