Flash Butt Welding Water Screen for Spatter Containment
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Solution Overview
Problem
Conventional spatter collection apparatuses in flash butt welding require routine cleaning to remove adhering spatters, which is troublesome due to incomplete spatter removal.
Innovation Solution
A spatter scattering prevention apparatus that forms a water screen around the welding spot using multiple nozzles with rectifying nozzle portions to catch and collect spatters, reducing the need for cleaning by ensuring spatters fall and are collected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective cover with water injection is used to prevent spatter scattering, then spatter containment is improved, but maintenance complexity increases due to incomplete spatter removal requiring routine cleaning
Solution Approach 1:
The invention extracts the spatter collection function from the protective cover by introducing a separate collection tray positioned beneath the welding spot. Spatters fall vertically onto the tray instead of adhering to the cover's inner surface, separating the containment function (cover) from the collection function (tray) and eliminating the need to clean the cover.
Solution Approach 2:
The collection tray acts as an intermediary device between the welding spot and the ground. It intercepts falling spatters before they can adhere to the protective cover or peripheral devices, serving as a dedicated collection point that simplifies maintenance by concentrating all spatter removal in one accessible location.
2Quantity of substance
If a protective cover is used to catch spatters, then spatter collection is improved, but cleaning frequency increases due to spatter adhesion to the cover surface
Solution Approach 1:
The invention extracts the spatter collection function from the protective cover by introducing a separate collection tray positioned beneath the welding spot. Spatters fall vertically onto the tray instead of adhering to the cover's inner surface, separating the containment function (cover) from the collection function (tray) and eliminating the need to clean the cover.
Solution Approach 2:
The invention applies local quality by creating a specific collection zone (the tray) with properties optimized for spatter reception. The tray's position directly beneath the welding spot and its open top surface create a localized collection area that efficiently captures falling spatters while remaining easily accessible for quick cleaning.
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 apparatus effectively prevents spatter scattering, reducing maintenance workload by ensuring spatters are caught and collected, rather than adhering to protective covers or peripheral devices.
Implementation Method 1
configured to form a water screen in midair in the vicinity of a welding spot... by jetting water towards the welding spot
Implementation Method 2
spatters are caused to fall with the water screens and collected in a drain
Data Source
Figure 1~2
Figure 3~4
AI summary
Provided is a spatter scattering prevention apparatus that eliminates the necessity to, for example, remove scattered spatters and thus makes it possible to facilitate maintenance work, and also provided is a flash butt welder including the spatter scattering prevention apparatus. The spatter scattering prevention apparatus 1 according to the present invention is characterized by being configured to form a water screen in midair in the vicinity of a welding spot, at which welding is performed, wherein the water screen is for preventing spatters, generated during the welding, from scattering. The spatter scattering prevention apparatus is also characterized by being configured to form the water screen on one side in a lateral direction of the welding spot and form the water screen on the other side, laterally opposite to the one side, of the welding spot.