Pivoting Welding Torch for Narrow Chamfer Current Transfer
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Solution Overview
Problem
Conventional welding devices, such as those described in EP 1 287 937, are inadequate for welding narrow bevels with widths greater than 10 mm and thicknesses greater than 140 mm in two passes per layer due to a large torch body section that restricts electrode movement.
Innovation Solution
A welding device with a flexible plate power supply system that allows the torch body's lower part to pivot relative to the upper part, enabling electrode orientation changes and maintaining current transmission without impeding movement, along with a cam mechanism for controlled positioning and a cooling system to manage temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the torch body has a large cross-section to maintain structural integrity and current transmission, then the device can transmit welding current effectively, but the electrode cannot move from one edge of the bevel to the other in narrow chamfers
Solution Approach 1:
The torch body is divided into an upper part and a lower part that can move relative to each other. The lower part carries the electrode and can be positioned independently to reach across narrow bevels, while the upper part maintains the current transmission pathway through flexible plates connected to the power supply.
Solution Approach 2:
The torch body transitions from a rigid structure to a dynamic one where the lower part can move relative to the upper part. This movement capability allows the electrode to access narrow chamfer spaces while the upper part remains stationary for stable power supply connection.
2Ease of operation
If the lower part of the torch body is moved relative to the upper part to enable electrode repositioning, then the electrode can reach narrow bevel edges, but the flexible plate must bend which may impede movement or affect current transmission
Solution Approach 1:
Flexible plates made of copper or copper alloys are used to transmit current from the upper to the lower part of the torch body. These plates can bend slightly when the parts are not aligned, accommodating the movement of the lower part while maintaining electrical connectivity.
Solution Approach 2:
The flexible plates are designed with specific material properties (copper or copper alloys with thickness of 0.1 to 0.3 mm) that allow them to change shape elastically during torch body movement while maintaining sufficient electrical conductivity for reliable current transmission.
3Ease of operation
If the upper and lower parts of the torch body form a significant angle to access narrow chamfers, then the electrode can reach difficult positions, but gas losses increase at the gap between parts
Solution Approach 1:
The flexible plates not only transmit current but also help seal the gap between the upper and lower parts of the torch body. When the parts form an angle, the flexible plates bend to maintain contact and reduce gas leakage at the junction, preserving shielding gas effectiveness.
4Adaptability or versatility
If a flexible connection is used between upper and lower sections of the conduit to accommodate movement, then the torch can adjust to narrow bevels, but the flexible connection is exposed to high temperatures and has a short lifespan
Solution Approach 1:
The flexible connection is extracted from the high-temperature zone by placing it in the upper part of the torch body that remains relatively cool, while the lower part exposed to welding heat uses rigid or heat-resistant components. This separates the flexible connection from the thermal stress environment.
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
Enables efficient welding in narrow bevels with widths greater than 10 mm and thicknesses between 20 mm and 200 mm, reducing gas loss and allowing for flexible use in various applications, including hybrid laser-arc welding for improved fusion.
Implementation Method 1
The use of a flexible plate to transmit current from the upper to the lower part of the torch body allows the welding current to be transferred to the electrode, regardless of the position of the lower part of the torch body
Implementation Method 2
along with a cam mechanism for controlled positioning and a cooling system to manage temperature
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a welding device (1) comprising: a torch body (19); and an electrode (21). The torch body (19) comprises an upper portion (37) connected to the torch holder (17), a lower portion (39) and a pivoting linkage (41) between the lower portion (39) and the upper portion (37). The electrical power supply (23) comprises an electrical current lead (79) through the upper portion (37); a current passage (81) through the lower portion (39), said current passage being electrically connected to the electrode (21); and at least one flexible plate (83) electrically connecting the current lead (79) to the current passage (81).