Handheld Filler Wire Advancement Device for TIG Welding
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Solution Overview
Problem
TIG welding operators face difficulty in manually manipulating and feeding filler wire due to its length and the need to expose additional material, requiring improved methods for filler wire advancement.
Innovation Solution
A handheld filler wire advancement device with a motor-driven assembly that automatically feeds the filler wire into the weld pool, reducing operator input and enhancing wire management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually manipulates the filler wire with a single hand, then the welding operation can be performed, but the difficulty of manipulation increases due to the wire length and the need to expose additional material
Solution Approach 1:
The patent introduces a filler wire spool and a filler wire guide as intermediary components between the filler wire rod and the weld pool. The spool holds the wire and the guide directs it toward the weld pool, automating the feeding process and eliminating the need for manual manipulation of the wire by the operator.
Solution Approach 2:
The system is configured to automatically feed the filler wire from the spool through the guide to the weld pool without requiring operator intervention. The wire feeding process serves itself through the mechanical arrangement of the spool and guide, reducing the operational burden on the welder.
2Manufacturing precision
If the operator feeds the filler wire forward and pulls it backward manually, then the desired quantity and placement of filler material can be obtained, but operator fatigue increases
Solution Approach 1:
The filler wire guide acts as an intermediary that automatically positions and directs the filler wire to the weld pool with precise placement. This eliminates the need for the operator to manually feed and pull the wire, reducing fatigue while maintaining precision through the guided delivery system.
3Ease of operation
If a handheld device with motor-driven assembly is used to automatically feed filler wire, then operator fatigue is reduced and precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the motor-driven wire feeding mechanism from the traditional welding torch and integrates it into a separate handheld device. This allows the welding torch to remain simple while the wire feeding function is automated in a dedicated component, reducing overall system complexity while maintaining automation benefits.
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 device allows for consistent and uniform weld bead formation by automating the filler wire feed, reducing operator fatigue and improving the precision of filler material placement.
Implementation Method 1
a motor disposed within the casing and coupled to the drive assembly to provide the drive assembly with power for movement of the rod of filler wire
Data Source
AI summary
A handheld filler wire advancement device is provided. The device includes a casing having an opening extending axially through the casing for receiving a rod of filler wire, wherein the casing comprises a feed rate selection feature that enables selection of a desired filler wire feed rate and a pull back to feed forward ratio selection feature that enables selection of a pull back to feed forward ratio. The device also includes a drive assembly disposed within the casing and adapted to contact the rod of filler wire to advance and retract the rod of filler wire within the opening of the casing consistent with the desired filler wire feed rate and the pull back to feed forward ratio. Further, the device includes a motor disposed within the casing and coupled to the drive assembly to provide the drive assembly with power for movement of the rod of filler wire.