Flexible Welding Torch Cooling for Stable Nozzle Positioning
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Solution Overview
Problem
Existing welding torches with rigid connecting elements are inflexible and require frequent replacement to adapt to different spatial configurations, leading to increased time and cost in welding operations, especially during high-energy processes where they often overheat due to inadequate cooling.
Innovation Solution
A welding torch with a flexible, tubular connecting element that includes a fluid-cooled heat exchanger, allowing for adjustable nozzle positioning and effective cooling using a cooling fluid like water, which maintains the nozzle assembly's stability and prevents overheating during high-energy welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid connecting element is used between torch holder and nozzle holder, then structural stability is improved, but adaptability to different spatial configurations deteriorates
Solution Approach 1:
The patent applies a flexible connecting element (flexible hose or corrugated tube) between the torch holder and nozzle holder, replacing rigid connecting elements. This flexible element can be bent and positioned at different angles to adapt to various spatial configurations while maintaining structural integrity and stability during welding operations.
2Adaptability or versatility
If a flexible connecting element is used between torch holder and nozzle holder, then adaptability to different spatial configurations is improved, but cooling efficiency deteriorates
Solution Approach 1:
The patent incorporates a cooling fluid conduit running through the flexible connecting element, enabling hydraulic cooling to reach the nozzle holder. This allows efficient heat removal via circulating cooling fluid while maintaining the flexibility needed for spatial adaptation, resolving the contradiction between flexibility and cooling efficiency.
3Device complexity
If gas cooling is used in high-energy welding processes, then simplicity of cooling system is improved, but cooling effectiveness deteriorates
Solution Approach 1:
The patent transitions from gas cooling to hydraulic cooling by introducing a cooling fluid conduit that delivers cooling fluid directly to the nozzle holder. This hydraulic cooling system provides superior heat removal capability for high-energy welding processes compared to gas cooling, while the conduit is integrated into the flexible connecting element to maintain system compactness.
4Adaptability or versatility
If copper pipe bend is used for flexible welding torch, then flexibility and stability are improved, but durability deteriorates due to fatigue
Solution Approach 1:
The patent employs a composite structure for the flexible connecting element, combining flexible hose or corrugated tube materials that resist fatigue with integrated cooling fluid conduits. This composite approach maintains the flexibility needed for positioning while significantly improving durability by eliminating the fatigue problems associated with copper pipe bends through repeated bending cycles.
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 flexible and stable operation during high-energy welding with currents up to 220 A and wire diameters of 1.2 mm or more, allowing for quick cooling and reducing the risk of nozzle damage, thus improving operational efficiency and reducing costs by allowing manual adjustment of the nozzle assembly's orientation.
Implementation Method 1
a fluid-cooled heat exchanger connected to the at least one line... The connecting element carries a line for a cooling fluid, for example water, from the torch holder to the nozzle holder
Implementation Method 2
The nozzle holder (3) comprises a fluid-cooled heat exchanger (9) connected to the at least one line
Data Source
Figure 1~2
Figure 3
Figure 4~8
AI summary
The invention relates to a welding torch, comprising a nozzle stock for receiving a contact tube and a gas nozzle in particular for MIG/MAG gas-shielded welding, a torch holder, and a flexible, tubular connection element which connects the nozzle stock and the torch holder to one another and is designed to adjust a stable position of the nozzle stock and arc components, which are arranged preferably in the nozzle stock, such as a welding wire and/or an electrode, relative to the torch holder, wherein the connection element conducts a wire guiding core and/or the welding wire or the electrode, a duct for conducting gas, such as shielded gas, to the gas nozzle as well as a current conductor from the torch holder to the nozzle stock. The connection element further conducts at least one line for a cooling fluid, such as water, from the torch holder to the nozzle stock, and the nozzle stock comprises a fluid-cooled heat exchanger that is connected to the at least one line.