Hose End Welding with Overlapping Partial Seams for Leak Tightness
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Solution Overview
Problem
Existing methods for welding hose ends often result in weakened seams due to 'cat eyes' formation and leakage issues, particularly with larger wall thicknesses, as well as mechanical stress and excessive material deformation.
Innovation Solution
A two-step welding method is proposed, where a protective layer is applied inside the hose end to prevent welding of the interior, with clamping jaws applying partial seams that cover a significant circumference, ensuring leak-tightness and allowing for asymmetrical, overlapping seams that cover up to 120% of the circumference, while preventing excessive mechanical load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is applied to prevent welding of the inside, then leakage is reduced, but the welding process becomes more complex
Solution Approach 1:
The protective layer is applied to the inside surface of the hose end before the welding process begins. This preliminary protective measure prevents the welding heat from fusing the inner surfaces, thereby preventing leakage while allowing the outer surfaces to be welded effectively.
Solution Approach 2:
The welding process is divided into multiple sequential steps: first welding the outer surfaces with clamping jaws, then removing the protective layer, and finally welding the inner surfaces. This segmentation allows each welding operation to be optimized independently, improving overall reliability without excessive complexity.
2Reliability
If clamping jaws cover a larger circumference, then weld tightness improves, but mechanical load on the hose material increases
Solution Approach 1:
The clamping jaws are designed to apply localized pressure only at the joint region where welding is required, rather than distributing force across the entire hose circumference. This concentrates the mechanical load where it is most effective for creating a tight weld, while avoiding excessive stress on other parts of the hose material.
Solution Approach 2:
The clamping jaws cover a circumference that is sufficient to ensure weld tightness (up to 120% of the joint circumference) but not excessively large. This partial coverage provides adequate mechanical support and heat distribution for reliable welding without subjecting the entire hose to unnecessary mechanical stress.
3Ease of manufacture
If the hose is deflected to form cat eyes, then the welding location is accessible, but the weld strength is weakened
Solution Approach 1:
The hose ends are deflected to form cat eyes before the welding process begins, creating accessible welding locations. This preliminary geometric modification allows welding tools and clamping jaws to easily access the joint area, improving manufacturing ease while the subsequent welding process compensates for any potential strength reduction.
Solution Approach 2:
The cat eye formation changes the geometric parameters of the hose end, creating an angled or curved surface that improves weld accessibility. The welding process parameters (temperature, pressure, duration) are then adjusted to compensate for the geometric change and maintain adequate weld strength despite the altered hose configuration.
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
This method enhances the tightness of the weld, reduces leakage, and allows for larger markings, while preventing weakening at 'cat eyes' and mechanical damage, effectively addressing the limitations of existing techniques.
Implementation Method 1
the protective layer prevents a welding of the inside of the first hose end
Implementation Method 2
pressing the first hose end and the second hose end together flat at the joint between two first clamping jaws that are moved towards each other; welding the first hose end and the second hose end together by two first partial seams while pressed together
Data Source
AI summary
A method for welding a first hose end at a joint with a second hose end in a seam that extends on a circumference of the first hose end, the method comprising the steps: applying a protective layer at the joint to an inside of the first hose end; pushing the second hose end beyond the joint over the first hose end; pressing the first hose end and the second hose end together flat at the joint between two first damping jaws that are moved towards each other; welding the first hose end and the second hose end together by two first partial seams while pressed together, wherein the protective layer prevents a welding of the inside of the first hose end; releasing the first hose end and the second hose end from the two first clamping jaws after welding the two first partial seams.