Insulating Extension Tube for Deep Narrow Recessed Welding
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Solution Overview
Problem
Conventional contact tips are inadequate for reaching deep and narrow recessed weld joints due to their short length and conductive materials, leading to wire shorting and control issues during narrow groove welding.
Innovation Solution
A welding assembly with a contact tip and extension tube, where the extension tube is made of insulating material to prevent shorting and can be secured via fasteners, allowing for longer stick out and better reach into narrow gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional short contact tip made of conductive material (copper) is used, then the contact tip can be easily manufactured and provides good electrical conductivity, but it cannot reach deep and narrow recessed weld joints and causes wire shorting when it contacts the sidewall
Solution Approach 1:
The contact tip is divided into two separate components: a copper contact tip body that provides electrical conductivity and contact with the wire, and a separate insulating extension tube that extends the reach into narrow gaps. This segmentation allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
An insulating extension tube made of ceramic or other electrically insulating material is introduced as an intermediary component between the conductive copper contact tip and the workpiece environment. This extension tube allows the contact tip to reach deeper into narrow recessed areas while preventing electrical shorting to the sidewalls.
2Length of moving object
If the welding wire stick out length is increased to exceed three inches, then the wire can reach deep recessed portions, but the wire becomes bent and cumbersome and difficult to control
Solution Approach 1:
The insulating extension tube serves as a rigid intermediary structure that provides a straight pathway for the welding wire to follow into the narrow recessed gap. This prevents the wire from bending and becoming cumbersome, while still achieving the necessary reach depth.
Solution Approach 2:
The extension tube provides a rigid guiding structure that constrains the flexible welding wire to follow a straight path, preventing unwanted bending while allowing the wire to reach deep into the workpiece geometry.
3Use of energy by moving object
If the contact tip is made from a good electrical conductor like copper, then electrical conductivity is optimized, but any contact with the surrounding wall creates a short in the system
Solution Approach 1:
The contact tip system is segmented into a conductive copper portion that maintains electrical contact with the welding wire, and an insulating extension tube portion that extends into the work environment without conducting electricity to the sidewalls.
Solution Approach 2:
Different portions of the contact tip assembly have different electrical properties: the copper contact tip body is highly conductive where it contacts the wire, while the extension tube is electrically insulating where it interacts with the surrounding environment, preventing shorting.
4Length of moving object
If the contact tip length is extended to reach deep recessed gaps, then reach is improved, but the tendency for spurious arcing to occur between the welding wire and side walls increases
Solution Approach 1:
The insulating extension tube acts as an intermediary barrier between the welding wire and the conductive sidewalls of the recessed gap. This prevents spurious arcing by blocking the electrical path that would otherwise exist between the wire and the sidewalls.
Solution Approach 2:
The insulating extension tube creates an electrically inert environment around the welding wire by preventing electrical contact with the surrounding conductive surfaces, thereby eliminating the conditions necessary for spurious arcing.
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 solution enables efficient and cost-effective welding in deep and narrow recessed areas by preventing shorting and improving wire control, reducing labor and material costs.
Implementation Method 1
The extension tube can be made of insulating material such as ceramic, and consequently protects the welding wire from coming into contact with the side wall of the gap, thus avoiding a short
Implementation Method 2
The welding wire acts as a consumable electrode and is fused into an electric arc. The electric arc is created between the welding wire and the base material and melts the metals at the weld joint
Data Source
AI summary
A contact tip for hot-wire welder is provided that are adapted to operate in deep and narrow recessed gaps within a work piece. Contact tips in accordance with the current invention provide for an assembly having a body portion with a cavity and an extension portion which is inserted into the cavity. The extension portion is non-electrically conductive and allows the contact tip assembly to reach into deep, narrow grooves without worry of shorting the contact tip of the consumable.