Robotic Welding Fume Extractor with Rotating Duct

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Solution Overview

Problem

Existing fume extraction systems for robotic welding torches are inefficient in capturing fumes close to the point of generation due to limited mobility and entanglement of fume hoses during rotation, leading to reduced capture efficiency and increased downtime for installation and maintenance.

Innovation Solution

A fume extraction system that includes a neck clamp, intermediate mount, and fume duct capable of rotating with the welding torch, allowing for effective capture of fumes near the nozzle while maintaining access and reducing collision risks, with a fume manifold and hose configuration that communicates negative pressure for efficient fume collection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If a fume extractor is attached to a robotic welding torch to capture fumes close to the source, then fume capture efficiency is improved, but the fume hose becomes entangled during torch rotation

Engineering Contradiction:

Improvefume capture efficiencyVSAvoidhose entanglement during rotation

Core Design Contradiction:

Object-generated harmful factorsVSEase of operation

Solution Approach 1:

The fume extraction system is designed to rotate dynamically with the welding torch, allowing the fume duct to follow the torch through its range of motion. This dynamic configuration maintains optimal positioning for fume capture while preventing hose entanglement through coordinated rotational movement of the entire extraction assembly.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The fume duct is positioned concentrically around the welding torch neck, with the extraction system nested within the torch assembly. This nested configuration allows the fume duct to rotate with the torch without creating external entanglement issues, as the duct is integrated into the torch structure itself.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Stability of the object's composition

If a rigid fume extraction system is used, then structural stability is improved, but collision with external surfaces increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidcollision with external surfaces

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The fume duct is constructed from flexible material that can bend and deform when contacting external surfaces. This flexibility allows the duct to deflect away from obstacles during torch movement, preventing damage to both the duct and workpiece while maintaining the structural integrity of the overall extraction system.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible duct design inherently provides cushioning against collisions before they can cause damage. The duct's ability to deform absorbs impact energy during potential collisions with workpieces or fixtures, preventing more serious damage without requiring additional protective mechanisms.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Object-generated harmful factors

If the fume extractor follows the welding torch closely, then fume capture efficiency is improved, but installation and maintenance downtime increases

Engineering Contradiction:

Improvefume capture efficiencyVSAvoidinstallation and maintenance downtime

Core Design Contradiction:

Object-generated harmful factorsVSLoss of time

Solution Approach 1:

The fume extraction system is divided into modular components including a neck clamp assembly, intermediate mount, and fume duct sections. This segmentation allows for quick installation and maintenance by enabling individual components to be independently accessed, removed, or replaced without disassembling the entire system, significantly reducing downtime.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized modular design of the extraction system components allows them to be universally applied across different welding torch configurations. This multi-functionality enables rapid installation and maintenance using the same component set for various applications, reducing the time required for setup and servicing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system enhances fume extraction efficiency by capturing fumes closer to the source, reduces downtime for installation and maintenance, and minimizes collisions with external surfaces through flexible and resilient components.

Implementation Method 1

a fume manifold rotationally coupled to the intermediate mount and coupled to a fume hose, wherein the fume manifold, the intermediate mount, and the fume duct are configured to communicate a negative pressure from the fume hose to an end of the fume duct

Methodology Applied

Scientific EffectNegative pressure: Pressure Drop

Data Source

PatentUS20230182183A1Fume extractors for robotic welding torches

Publication Date: 2023.06.15 ILLINOIS TOOL WORKS INC

AI summary

An example fume extractor for a robotic welding torch includes: a neck clamp configured to attach to a neck of a robotic welding torch; an intermediate mount rigidly attached to the neck clamp; a fume duct coupled to the intermediate mount and extending over the neck of the robotic welding torch toward a nozzle of the robotic welding torch; and a fume manifold rotationally coupled to the intermediate mount and coupled to a fume hose, wherein the fume manifold, the intermediate mount, and the fume duct are configured to communicate a negative pressure from the fume hose to an end of the fume duct closest to the nozzle of the robotic welding torch.