Remote Flint Ignition for Safer Exothermic Weld Triggering
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Solution Overview
Problem
Existing exothermic welding methods pose a hazardous situation for technicians due to the proximity required during ignition of weld metal powder, which can result in exposure to sparks, flames, and hot gases.
Innovation Solution
A flint trigger device with a motor-driven flint wheel or mechanical mechanisms generates sparks to ignite a starting powder within an exothermic mold, allowing for remote initiation of the exothermic reaction, thereby reducing the risk of injury.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual ignition method is used, then the ignition process is simple, but the technician is exposed to sparks, flames and hot gasses creating a hazardous situation
Solution Approach 1:
The patent introduces an ignition powder as an intermediary substance that is poured into a hole in the mold cover. This intermediary allows the spark to ignite the weld metal powder remotely through the powder, rather than directly exposing the technician to the exothermic reaction. The ignition powder acts as a buffer medium between the ignition source and the hazardous reaction zone.
Solution Approach 2:
The patent replaces the manual mechanical ignition method (directly lighting the weld metal powder) with a controlled spark ignition system that uses an ignition powder medium. This substitution allows for safer remote ignition while maintaining the effectiveness of the exothermic reaction process.
2Object-affected harmful factors
If remote ignition system is used, then the technician is protected from hazards, but the device complexity increases with controller and flexible cable
Solution Approach 1:
The patent extracts the hazardous ignition function from the direct contact zone and places it in a remote location. The controller and flexible cable system separates the ignition initiation (remote, safe location) from the ignition execution (at the mold), allowing the technician to operate from a protected position while still achieving reliable ignition.
Solution Approach 2:
The ignition system is designed to be universally applicable to different mold configurations and welding scenarios. The flexible cable allows the controller to be positioned conveniently, and the system can accommodate various mold sizes and types, making the remote ignition solution broadly useful across different exothermic welding applications.
3Reliability
If ignition powder is poured into mold hole, then the ignition is effective, but the technician must be in close proximity to the mold creating safety risks
Solution Approach 1:
The ignition powder serves as a mediator that enables effective ignition transmission from the spark source to the weld metal powder. By pouring the ignition powder into the mold hole beforehand, the system ensures that when the spark is generated (even remotely), the ignition powder will reliably transmit the ignition energy to start the exothermic reaction, maintaining ignition effectiveness while allowing safer operator positioning.
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
The flint trigger device enables safe and controlled ignition of exothermic reactions, minimizing exposure to hazardous conditions and ensuring a reliable welding process.
Implementation Method 1
rotation of the motor causes the flint and flint wheel to generate one or more sparks
Implementation Method 2
The ignition powder ignites the powder starting the exothermic reaction
Implementation Method 3
When the weld metal powder is ignited, an exothermic reaction is created within the mold. The exothermic reaction liquefies the powder and the disc of welding material
Data Source
AI summary
Trigger devices for igniting an exothermic reaction is provided. The trigger devices may be flint type trigger devices and electronic type trigger devices. The flint type trigger device has a housing with a spark opening on a rear wall of the housing. A mold mounting assembly is secured to an exterior of the rear wall of the housing. A motor assembly is secured to the inside of the rear wall of the housing. The motor assembly has a flint wheel attached to a shaft of a motor, where the flint wheel is located adjacent the spark opening. A flint assembly is positioned within the housing such that a flint of the flint assembly is in contact with the flint wheel. A controller positioned within the housing is configured to selectively activate the motor to cause the flint wheel to rotate against the flint to create one or more sparks that are ejected from the spark opening.