Movable Welding Torch Assembly for Precise Thick-Plate Grooves
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Solution Overview
Problem
Existing welding torch assemblies face inefficiencies and inaccuracies when welding thick metal plates due to the need for larger grooves to accommodate the torch, leading to excessive material usage and poor weld quality.
Innovation Solution
A welding torch assembly with a movable distal part and actuator system, allowing precise orientation and reduced material usage, featuring a controller for incremental movement and dual electrode wires, along with a welding powder distributor to maintain welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the welding torch is made larger to accommodate thick plate welding, then the welding capability is improved, but the groove size must be increased leading to excessive material usage and poor weld quality
Solution Approach 1:
The welding torch is divided into two separate torches that can operate independently or simultaneously. This segmentation allows each torch to be optimized for specific welding tasks within the groove, enabling effective welding of thick plates without requiring an oversized single torch that would necessitate larger grooves and excessive material consumption.
Solution Approach 2:
One welding torch is positioned inside the groove while the other operates from outside the groove. This nested arrangement allows both torches to work in conjunction, with the internal torch accessing the groove valley and the external torch providing supplementary welding, thereby maintaining groove integrity and reducing material usage while preserving strong welding capability.
2Ease of operation
If the groove opening is made larger to accommodate the welding torch, then the torch positioning is improved, but more welding material is required leading to inaccurate welding and low quality welds
Solution Approach 1:
The welding operation is segmented into two coordinated torches: one positioned inside the groove for precise work in the groove valley, and another outside the groove for supplementary welding. This segmentation enables both torches to work within a controlled groove geometry, maintaining positioning ease while preventing the need for oversized grooves that would compromise weld accuracy and quality.
3Device complexity
If a single welding torch is used for thick plate welding, then the device complexity is reduced, but the welding precision and efficiency are compromised
Solution Approach 1:
The welding system is segmented into two specialized torches mounted on a common holder assembly, each capable of independent positioning and operation. This segmentation provides the welding precision needed for thick plate applications while maintaining reasonable device complexity through shared mounting structures and coordinated control mechanisms.
Solution Approach 2:
Two welding torches are merged into a single integrated holder assembly that can position and coordinate both torches simultaneously. This merging approach achieves high welding precision for thick plates while consolidating control and mounting functions, thereby managing device complexity effectively.
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
Enhances welding precision and efficiency by minimizing material consumption and improving weld quality, enabling smaller gap dimensions and reduced wear on equipment.
Implementation Method 1
an actuator coupled to the distal part and the proximal part configured to move the distal part of the welding torch assembly with respect to the proximal part
Implementation Method 2
the electrode wire feeder is configured to feed at least two electrode wires to the welding torch through the welding torch holder
Implementation Method 3
the welding torch is configured to weld a groove, connecting two metal sheets, when a current is applied through at least some of the two or more electrode wires fed to the welding torch
Data Source
Figure 1~2
Figure 3A~3C
Figure 4
AI summary
The invention provides A welding torch assembly for a welding device, the welding torch assembly comprising a frame, a proximal part, coupled to the frame, comprising an electrode wire feeder, a distal part, comprising a welding torch holder, the welding torch holder configured to hold a welding torch to the distal part, a hinge for moveably coupling the distal part to the proximal part; and an actuator coupled to the distal part and the proximal part configured to move the distal part of the welding torch assembly with respect to the proximal part, wherein the electrode wire feeder is configured to feed two electrode wires to the welding torch through the welding torch holder, and the welding torch is configured to weld a groove, connecting two metal sheets, when a current is applied through the two electrode wires fed to the welding torch.