Arc Welding Torch Nozzle Layout for Source-Close Fume Capture
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Solution Overview
Problem
Existing arc welding torches face limitations in handling and safety due to restricted operation by extraction devices, with insufficient fume extraction volume flow and potential inhalation of harmful gases, as the flue gas is guided through a bypass line parallel to the torch neck, limiting handling and failing to effectively capture pollutants close to the source.
Innovation Solution
A combined extraction/shielding gas nozzle design with radially and axially offset channels allows for compact construction, optimal smoke extraction, and safe operation by positioning extraction openings behind the shielding gas channel, ensuring effective capture of fumes close to the welding process without altering the torch head, and integrating the extraction device with the torch handle to eliminate the bypass line, thus enhancing fume extraction efficiency and user safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flue gas is guided through a bypass line parallel to the torch neck, then the extraction device can be integrated, but the handling is restricted and the fume extraction volume flow is insufficient
Solution Approach 1:
The patent combines the extraction channel and shielding gas channel into a single integrated nozzle structure. The extraction opening is positioned in the front region of the nozzle, merging the previously separate bypass line function directly into the torch head, eliminating the need for a parallel bypass line and improving handling while maintaining extraction effectiveness
Solution Approach 2:
The extraction channel is positioned radially offset from the shielding gas channel, with the extraction opening located in the front region rather than parallel to the torch neck. This spatial reconfiguration in radial and axial dimensions allows effective fume extraction while improving torch handling characteristics
2Productivity
If the extraction opening is positioned in the front region, then fume extraction efficiency is improved, but the shielding gas flow may be affected
Solution Approach 1:
The nozzle is designed with radially offset channels that segment the flow paths. The extraction channel and shielding gas channel are positioned radially offset from each other, allowing independent optimization of each function. The extraction opening faces radially outward to efficiently capture fumes, while the shielding gas channel maintains its flow path, ensuring both functions operate reliably without interfering with each other
Solution Approach 2:
The extraction opening is positioned in the front region of the nozzle where fume concentration is highest, creating a localized extraction zone with optimal extraction efficiency. The radially offset channel configuration provides local quality differentiation, allowing the extraction function to be optimized in the front region while the shielding gas flow is maintained through its dedicated channel path
3Volume of moving object
If radially offset channels are used, then compact construction is achieved, but manufacturing complexity increases
Solution Approach 1:
The extraction channel and shielding gas channel are merged into a single integrated nozzle body with radially offset channels. This consolidation eliminates the need for separate bypass lines and multiple components, achieving compact construction while the radial offset configuration actually simplifies manufacturing by allowing straightforward channel formation through conventional machining or molding techniques
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
This design achieves improved fume extraction efficiency, protects welders from harmful emissions, and maintains a compact, lightweight form factor similar to conventional torches, ensuring effective shielding gas flow and reduced heating of the nozzle, while ensuring ozone extraction and handling ease.
Implementation Method 1
an extraction device (3) with at least one extraction channel (6) with an extraction opening (7) for extracting the flue gas or pollutants produced during the welding process
Implementation Method 2
a shielding gas channel (1) with a shielding gas outlet opening (2) for supplying shielding gas to the welding process
Implementation Method 3
Arc welding torches generate an arc between the workpiece and a melting or non-melting welding electrode to melt the materials
Data Source
AI summary
A combined extraction/shielding gas nozzle (10) of an arc welding torch with a consumable electrode has a shielding gas channel (1) for supplying shielding gas to the welding process and has an extraction device (3) with at least one extraction channel (6) with an extraction opening (7) for extracting the flue gas produced during the welding process. The shielding gas channel (1) and the at least one extraction channel (6) are disposed radially and offset to one another in the axial direction such that the extraction opening (7) for the at least one extraction channel (6) lies behind the shielding gas channel (1) in the direction of flow of the flue gas.