Resistance Welding Wire Connector for CO2 Gas Welding
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Solution Overview
Problem
In CO2 gas welding, the process of replacing welding wires is inefficient, leading to unnecessary consumption and increased costs due to the need to discard residual wire when switching from an old wire to a new one, which disrupts productivity.
Innovation Solution
A device that connects old and new welding wires using electrical resistance heating, featuring a base frame, electrode plates, clampers, and a power supplier, allowing for seamless transition without discarding residual wire, with a moving member and elastic support for precise alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If residual welding wire is discarded when replacing old wire with new wire, then welding quality and process reliability are maintained, but wire consumption increases and cost increases
Solution Approach 1:
The invention recovers the residual welding wire by connecting it to the new welding wire through resistance welding, rather than discarding it. The connecting device includes electrode plates that clamp and resistance-weld the old and new wires together, allowing the residual wire to be fully utilized and connected to the welding torch, thus eliminating waste while maintaining process reliability
Solution Approach 2:
The invention replaces the manual mechanical connection method with an automated resistance welding system. The connecting device uses electrical current to generate heat at the contact point between old and new wires, creating a strong metallurgical bond automatically, which substitutes the traditional mechanical splicing or discarding process
2Productivity
If residual welding wire is discarded when replacing old wire with new wire, then welding process simplicity is maintained, but productivity decreases
Solution Approach 1:
The wire replacement process is segmented into distinct functional components: the connecting device with electrode plates for clamping and resistance welding, the clamping mechanism for securing wires, and the power supply for generating welding current. This segmentation allows each component to perform its specific function efficiently, enabling automated wire connection that improves productivity despite the added device complexity
Solution Approach 2:
The connecting device acts as an intermediary between the old welding wire and the new welding wire, providing a controlled environment for resistance welding. The electrode plates and clamping mechanism serve as intermediate structures that hold the wires in position and apply the necessary pressure and heat to create a reliable connection, facilitating seamless wire transition
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 solution reduces unnecessary wire consumption and costs by allowing for continuous operation without discarding residual wire, enhancing productivity in CO2 gas welding processes.
Implementation Method 1
the old wire and the new wire may be connected by electrical resistance heating through the electric power supplied from the power supplier
Data Source
AI summary
A device for connecting welding wires for CO2 gas welding includes a base frame, first and second electrode plates that are disposed apart from each other on the base frame and including disposing grooves to which an old wire and a new wire are respectively disposed, and clampers that are disposed to each electrode plate and that clamp the used wire and the new wire disposed to the disposing grooves, respectively.