Rotary Welding Torch with Intersecting Channels

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Solution Overview

Problem

Current robotic welding torches suffer from mechanical wear in cables due to fixed positioning, leading to coolant leaks and voltage variations, which affect the welding process and weld quality.

Innovation Solution

A rotary welding torch design with a supply conduit providing inert gas, coolant, and electrical current, featuring a rotary welding assembly that allows clockwise and counterclockwise rotation, utilizing a rotary coolant assembly with intersecting channels for continuous flow and stress reduction on cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the welding torch is fixed in position, then the structure is simple and easy to manufacture, but the cables are subjected to severe mechanical wear during robotic arm articulation

Engineering Contradiction:

Improvetorch structure simplicityVSAvoidcable durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a rotary joint mechanism that allows the welding torch to rotate dynamically with the robotic arm while maintaining continuous supply of coolant and electrical current. This dynamic solution replaces the static fixed connection, enabling the torch to follow the arm's articulation without creating excessive cable stress or wear.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the robotic arm articulates freely, then the operational flexibility is high, but the cables experience mechanical wear leading to coolant leaks and voltage variations

Engineering Contradiction:

Improverobotic arm articulation freedomVSAvoidcable integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent introduces a rotary joint as an intermediary mechanism between the robotic arm and the welding torch. This intermediary component specifically handles the rotation and maintains continuous supply of coolant and electrical current, isolating the cables from the mechanical wear caused by arm articulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If the torch rotates during welding, then the welding coverage and adaptability improve, but the cables are damaged due to mechanical wear

Engineering Contradiction:

Improvetorch rotation capabilityVSAvoidcable lifespan

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The rotary joint serves as a specialized intermediary that enables torch rotation while maintaining reliable electrical and coolant connections. It specifically addresses the rotational movement needs without subjecting the cables to damaging mechanical wear.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If fixed cable connections are used, then the device complexity is low, but coolant leaks and voltage variations occur during rotation

Engineering Contradiction:

Improveconnection system simplicityVSAvoidcoolant and electrical supply stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces fixed static connections with a dynamic rotary joint system that maintains continuous coolant and electrical current supply during torch rotation. This dynamic connection system adapts to the rotational movement while preserving supply stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotary joint acts as an intermediary mechanism that specifically manages the rotation while maintaining stable coolant and electrical connections, isolating these critical supplies from the mechanical stresses of rotation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enables uninterrupted cooling and electrical current transfer during rotation, reducing mechanical stress on cables and enhancing the quality and reliability of the welding process by minimizing wear and leakage.

Implementation Method 1

utilizing a rotary coolant assembly with intersecting channels for continuous flow and stress reduction on cables

Methodology Applied

Scientific EffectFluid flow through intersecting channels:

Implementation Method 2

a supply conduit providing a supply of inert gas, coolant and electrical current

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

a stream of inert gas, such as helium or argon, is directed over the molten electrode wire to prevent oxygen and/or nitrogen from contacting the molten electrode wire

Methodology Applied

Scientific EffectInert atmosphere shielding:

Data Source

PatentUS9375801B2Rotary welding torch

Publication Date: 2016.06.28 ABICOR BINZEL USA INC

AI summary

A rotary robotic welding torch that enables the welding process in a robotic unit. The rotary welding torch allows for clockwise and counterclockwise rotation during the welding process, while being supplied with an uninterrupted supply of inert gas and electrical current. The rotary robotic welding torch may also be supplied with an uninterrupted supply of coolant and/or electrode/filler wire during the welding process.