Welding Nozzle Cleaner Roller Guide for Precise Cutter Centering
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Solution Overview
Problem
Conventional nozzle cleaners for gas arc welding nozzles face difficulties in precisely centering the cutter with respect to the welding nozzle, requiring separate driving sources and complex mechanisms, which complicates the removal of sputter from the inner peripheral surface.
Innovation Solution
A nozzle cleaner with a guide mechanism comprising insertion-side and cutter-side roller units, featuring hourglass-shaped guide rollers that align the welding nozzle with the cutter's central axis, allowing for easy centering and sputter removal without additional driving sources, utilizing a start switch activated by the moving roller to initiate cutter rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate driving source is used to drive the retainer and another separate driving source is used to drive the elevator for upward movement of the cutter, then the nozzle cleaner can perform sputter removal, but the device complexity increases and the centering precision of the cutter with respect to the welding nozzle deteriorates
Solution Approach 1:
The patent combines the driving functions into a single driving source that simultaneously drives both the retainer and the elevator mechanism. The driving source is coupled to the retainer through a transmission mechanism that includes a belt and pulleys, allowing one motor to control both the rotational movement of the retainer and the vertical movement of the cutter, thereby reducing the number of driving sources from two to one.
Solution Approach 2:
The single driving source performs multiple functions by being coupled to different components through the transmission mechanism. It simultaneously provides rotational motion to the retainer for holding and rotating the welding nozzle, and vertical motion to the elevator for positioning the cutter, making one driving source universal for multiple operational requirements.
2Ease of operation
If a separate driving source is used to drive the retainer and another separate driving source is used to drive the elevator, then the nozzle cleaner can perform sputter removal, but the manufacturing cost and maintenance complexity increase
Solution Approach 1:
The patent merges multiple driving functions into a single motor unit with an integrated transmission system. Instead of manufacturing and assembling two separate motors and their respective control systems, the design requires only one motor coupled to a belt-driven transmission mechanism that distributes power to both the retainer and elevator, simplifying the manufacturing and assembly processes.
3Manufacturing precision
If the cutter is moved upward using an elevator driven by a separate driving source, then the blade can be inserted toward the inner peripheral surface of the welding nozzle, but the centering precision of the cutter with respect to the welding nozzle deteriorates
Solution Approach 1:
By combining the driving of the retainer and elevator into a single synchronized system, the patent ensures that the vertical movement of the cutter and the rotational positioning of the retainer are coordinated. This synchronization, achieved through the belt transmission mechanism, maintains proper alignment and centering between the cutter and welding nozzle throughout the operation.
Data Source
AI summary
A nozzle cleaner having a configuration for centering a cutter thereof with respect to a welding nozzle. The nozzle cleaner peels off sputter from an inner peripheral surface of a welding nozzle by inserting the cutter toward the inner peripheral surface of the welding nozzle, and then rotating the cutter. The nozzle cleaner includes a guide mechanism to center the welding nozzle with respect to the cutter. The guide mechanism includes an insertion-side roller unit and a cutter-side roller unit, each having a pair of guide rollers having a smaller diameter portion and a pair of enlarged diameter portions. The enlarged diameter portions guide the welding nozzle to the vicinity of the central position of the corresponding smaller diameter portion. The facing guide rollers of the cutter-side roller unit and of the insertion-side roller unit are arranged in arrangement directions orthogonal to each other, respectively.