Handheld Electric Welder With Integrated Wire Feeding
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Solution Overview
Problem
Existing electric welders are cumbersome to carry and require frequent replacement of short welding rods during continuous operation, making them inconvenient to use.
Innovation Solution
An electric welder with an integrated shell, welding barrel, controller, and welding wire feeder, where the welding wire feeder is housed within the shell, allowing for continuous wire supply and reduced rod replacement, along with a mounting system for the wire disc that facilitates stable and flexible wire conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric welder uses a handheld welding gun design, then it is convenient to carry, but it requires frequent replacement of short welding rods during continuous operation
Solution Approach 1:
The patent combines the welding gun and welding rod storage/feeding mechanism into a single integrated handheld device. The welding rod is stored in a magazine within the handle, and an automatic feeding mechanism delivers the rod to the electrode holder, eliminating the need for frequent manual replacements while maintaining handheld portability.
Solution Approach 2:
The welding rod is pre-loaded into the magazine before operation begins. The automatic feeding mechanism prepares and delivers the rod in advance, so the operator does not need to stop and replace rods during continuous welding operations.
2Ease of operation
If the welding rod is short, then it can be easily handled, but it needs to be continuously supplemented during continuous operation
Solution Approach 1:
The welding system performs self-service through an automatic rod feeding mechanism. When the electrode holder runs out of rod, the mechanism automatically feeds the next section from the magazine without requiring operator intervention, thus eliminating time loss while maintaining the benefits of short, easily handled rod sections.
3Ease of operation
If the welding barrel, controller and welding wire feeder are installed in the shell to form an integral structure, then the welder is more convenient to carry, but the device complexity increases
Solution Approach 1:
The patent integrates the welding barrel, controller, and wire feeder into a single compact handheld unit with all components arranged within the shell. The wire feeder is positioned in the first chamber, the controller in the second chamber, and the welding barrel extends from the first chamber, creating a unified portable device.
Solution Approach 2:
The patent arranges components in three-dimensional space within the shell, utilizing vertical and horizontal positioning to fit all components in a compact form factor. The welding barrel extends along the longitudinal axis, while the wire feeder and controller are positioned in separate transverse chambers, optimizing space utilization.
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 design enhances portability and reduces the need for frequent welding rod replacements, making the electric welder more convenient to carry and use, with improved stability and flexibility in wire conveyance.
Implementation Method 1
the driving roller drives the welding wire clamped between the driving roller and the driven roller to move, and the driven roller rotates under an action of a friction
Implementation Method 2
the driven roller has a tendency to abut against the driving roller under the action of an elastic force of the elastomer
Implementation Method 3
the driving roller drives the welding wire clamped between the driving roller and the driven roller to move
Data Source
AI summary
The present application discloses an electric welder, and relates to a field of an electric welding equipment. The electric welder includes a shell, a welding barrel, a controller and a welding wire feeder; the shell includes a handheld part, and the welding barrel, the controller and the welding wire feeder are installed in the shell; the welding wire feeder is configured for conveying the welding wire into the welding barrel; the controller is configured for controlling a start and a stop of the welding wire feeder and an arcing of the welding wire. The welding barrel, the controller and the welding wire feeder are installed in the shell to form an integral structure, which makes the welder more convenient to carry. In addition, by providing the welding wire feeder, a frequent replacement of the welding rod during a welding process is reduced, and the overall operation is more convenient.