Rotary Changer Parallel Axis Drive for Welding Torch Tip Replacement
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Solution Overview
Problem
Existing rotary changers for welding torches suffer from deformation or damage due to heavy loads on spur and pinion gears during repeated tip replacement, as the gears mesh perpendicularly, leading to wear and tear.
Innovation Solution
A rotary changer design where each rotator is moved along its axis to align with the drive axis, using spring members to absorb impact and reduce friction, allowing for sliding contact and integral rotation without heavy loads on gear teeth, thus preventing deformation or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spur gear and pinion gear mesh perpendicularly to drive rotators, then rotational motion can be transmitted, but heavy load on gear teeth causes deformation or damage after repeated use
Solution Approach 1:
The patent replaces the traditional perpendicular gear meshing mechanism with a parallel axis connection mechanism. The drive shaft and rotator shafts are connected parallel to each other, eliminating the need for perpendicular spur and pinion gear meshing. This substitution of the mechanical transmission system removes the harmful perpendicular gear contact that caused heavy loads and deformation, while still achieving rotational motion transmission through a different mechanical arrangement.
2Productivity
If multiple rotators are changed repeatedly at tip replacement position, then contact tip replacement efficiency improves, but gear teeth suffer repeated heavy loads leading to damage
Solution Approach 1:
The patent replaces the gear-based perpendicular transmission system with a parallel axis connection system that allows multiple rotators to be driven without subjecting gear teeth to repeated heavy loads. The drive shaft connects parallel to rotator shafts, enabling efficient replacement of multiple contact tips while avoiding the strength degradation that occurs with repeated perpendicular gear meshing.
Solution Approach 2:
The patent divides the drive mechanism into separate parallel connection segments rather than using a single gear transmission system. Each rotator can be independently connected to the drive shaft through parallel axes, allowing segmented operation that maintains strength while enabling repeated replacements.
3Device complexity
If single drive motor drives multiple rotators through perpendicular gear meshing, then device complexity is reduced, but deformation or damage occurs at connection portions
Solution Approach 1:
The patent replaces the complex perpendicular gear meshing system with a simpler parallel axis connection mechanism. Instead of using spur gears and pinion gears that mesh at right angles, the drive shaft directly connects parallel to the rotator shafts, reducing mechanical complexity while improving reliability by eliminating the deformation-prone gear contact portions.
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 design enhances the efficiency and longevity of the rotary changer by minimizing wear on the rotators and gears, allowing for smooth and reliable contact tip replacement without causing deformation or damage, and reduces the need for additional power sources, resulting in a simpler and cost-effective configuration.
Implementation Method 1
a spring member configured to bias the rotator in the one direction along the rotational axis of the drive shaft
Implementation Method 2
Rotating the rotator with the second rotator, of which the second rotational axis is aligned with the first rotational axis, moved toward the rotator brings the engaging face into engagement with the engageable face
Data Source
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AI summary
A moving mechanism (13) brings the rotational axis (C2) of each driven rotator (8) into alignment with the rotational axis (C1) of a drive rotator (45), which has an engaging face (45b) extending along its rotational axis. Each driven rotator (8) has an engageable face (8d) extending along the rotational axis of the drive rotator (45). Rotating the drive rotator (45) while moving the driven rotator (8), of which the rotational axis (C2) is aligned with the rotational axis (C1), toward the drive rotator (45) will bring the engaging face (45b) into engagement with the engageable face (8d).