Internal Water-Cooled Welding Coil to Prevent Splashing
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Solution Overview
Problem
Existing power supply coils for electric resistance welding face challenges with water splashing during cooling, leading to degraded welding quality, reduced monitoring accuracy, and plasma device failures, while also being heavy and limiting pipe manufacturing size due to thickness requirements for stiffness and machining accuracy.
Innovation Solution
A lightweight internal water-cooled power supply coil design featuring a single-turn tubular metal coil with attached metal plates and a cover, incorporating partition members to direct cooling water flow efficiently, preventing water splashing and allowing for reduced thickness without compromising cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external water-cooling method is used to cool the power supply coil, then cooling efficiency is improved, but water splashing occurs which degrades welding quality and reduces monitoring accuracy
Solution Approach 1:
The cooling water channel is nested inside the power supply coil structure. The power supply coil has a hollow interior space that serves as the cooling water channel, allowing the cooling system to be integrated within the coil itself rather than external to it. This nesting approach enables efficient cooling while containing the water completely within the coil structure, preventing any water splashing outside.
Solution Approach 2:
The partition wall acts as an intermediary structure that divides the cooling water channel into multiple sections. This partition wall prevents water from moving freely within the channel and potential splashing, while still allowing heat to be dissipated effectively through the cooled coil structure.
2Strength
If power supply coil thickness is increased to ensure stiffness and machining accuracy, then structural integrity is improved, but weight increases and pipe manufacturing size is constrained
Solution Approach 1:
The cooling water channel is nested inside the power supply coil, utilizing the hollow interior space. This allows the coil to have sufficient thickness for structural integrity while the internal cooling channel occupies the space that would otherwise be solid material, effectively reducing the overall weight without compromising stiffness or machining accuracy.
3Reliability
If power supply coil thickness is increased to prevent melting from insufficient heat radiation, then thermal protection is improved, but weight increases and manufacturing flexibility is reduced
Solution Approach 1:
The cooling water channel is nested within the coil structure, allowing water to flow through the interior space. This provides active thermal protection by continuously removing heat from the coil, enabling the use of thinner coil walls that would otherwise be prone to melting, thus reducing weight while maintaining or improving thermal reliability.
Solution Approach 2:
A hydraulic cooling system using water flow through the internal channel provides thermal protection. The moving water absorbs and removes heat from the coil, offering dynamic thermal management that is more effective than passive thermal mass alone, allowing for reduced material thickness and weight.
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 cooling of the power supply coil, reduces weight, prevents water splashing, and allows for the manufacturing of large-diameter electric resistance welding steel pipes without issues, maintaining welding quality and monitoring accuracy.
Implementation Method 1
cooling water is jetted to cool the power supply coil for electric resistance welding
Implementation Method 2
incorporating partition members to direct cooling water flow efficiently
Implementation Method 3
a high-frequency current is applied to butting ends of a steel sheet formed into a tubular shape to perform the electric resistance welding
Data Source
Figure 1
Figure 2(A)~2(C)
Figure 3
AI summary
A power supply coil for electric resistance welding according to the present invention is a power supply coil for electric resistance welding for heating a steel pipe to be welded by electric resistance, a metal coil that has a single-turn tubular shape and has a pair of end surfaces facing each other in a circumferential direction; a pair of metal plates that is connected to the pair of end surfaces of the metal coil; a cover that is attached to at least one of outer surfaces and inner surfaces of the metal coil and the pair of metal plates; a side wall portion that is interposed between the metal coil and the cover and between the pair of metal plates and the cover; a supply pipe that supplies cooling water to a space surrounded by the metal coil, the pair of metal plates, the cover, and the side wall portion; and a discharge pipe that discharges the cooling water from the space.