Modular Welding Assembly With Mating Geometries for Flexible Setup

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Solution Overview

Problem

Conventional welding systems lack flexibility and convenience, as they are typically sold as complete systems and individual components are cumbersome to transport and configure for specific welding applications.

Innovation Solution

A modular welding system with interchangeable components featuring mating geometries that allow for easy coupling and configuration, enabling users to select and combine only the necessary components for specific welding tasks, reducing complexity and footprint.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a complete welding system is provided, then all welding functions are available, but the system lacks flexibility and is cumbersome to transport

Engineering Contradiction:

Improvesystem flexibilityVSAvoidsystem configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The welding system is divided into separate modular components including power supply, wire feeder, and torch assembly. Each component can be independently selected, configured, and transported, allowing users to assemble only the necessary parts for specific welding applications rather than transporting entire complete systems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular components are designed with standardized interfaces and mating geometries that enable them to be combined in various configurations. The power supply can work with different wire feeders and torch types, creating a universal platform that adapts to multiple welding applications while maintaining system compatibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If individual components are separated, then flexibility and transportability improve, but coupling and configuration become inconvenient

Engineering Contradiction:

Improvetransport convenienceVSAvoidassembly convenience

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The mating geometries between components feature asymmetric shapes with complementary male and female interfaces. This asymmetric design provides unique orientation and alignment, ensuring that components can only be coupled in the correct configuration, thereby simplifying assembly while maintaining transportability of individual parts.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Standardized coupling mechanisms serve as intermediaries between different welding components. These intermediary interfaces mediate the connection between power supply, wire feeder, and torch, providing a standardized method for easy assembly and disassembly without requiring complex alignment or specialized tools.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11524357B2Modular welding system

Publication Date: 2022.12.13 ILLINOIS TOOL WORKS INC

AI summary

A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.