Rotary Welding Torch Wire Lock Mechanism
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Solution Overview
Problem
Rotary welding torches face accuracy issues due to variations in electrode wire stick out distance caused by wire contraction or extension during robotic arm movement, and existing wire brakes interfere with the welding process or restrict bidirectional rotation.
Innovation Solution
An integrated wire lock within the rotary welding torch uses pressurized air to maintain the wire stick out distance by gripping the electrode wire, allowing unrestricted bidirectional rotation and preventing interference with surrounding tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wire brakes are mounted outside the torch housing to secure the wire rigidly, then wire stability is improved, but the device size increases and interferes with the welding process
Solution Approach 1:
The wire lock mechanism is nested inside the torch housing, with the lock receiver and piston integrated into the existing torch structure. The electrode wire passes through the central conduit of the lock receiver, which is positioned within the central bore of the torch, allowing the wire clamping function to be embedded without increasing external dimensions.
Solution Approach 2:
The wire lock function is merged with the existing torch structure by integrating the lock receiver into the torch body and using the same central bore for both wire passage and lock receiver positioning. This combines the wire securing function with the existing torch housing rather than adding a separate external component.
2Stability of the object's composition
If wire brakes are used to secure the wire rigidly during robotic arm movement, then wire stick out distance control is improved, but bidirectional rotation capability is restricted
Solution Approach 1:
The wire lock mechanism transitions from a static rigid connection to a dynamic controllable state. The piston can move between unlocked and locked positions based on air pressure, allowing the system to adapt between free rotation during positioning and rigid wire securing during welding operations, enabling both bidirectional rotation and stable wire control.
Solution Approach 2:
Air pressure is used to actuate the piston, providing a clean and controllable means to engage and disengage the wire lock. The air channel delivers pressurized air to move the piston into the locked position, while release of air pressure allows the spring to return the piston to the unlocked position, enabling bidirectional rotation without mechanical complexity.
3Volume of moving object
If the wire lock is integrated into the torch housing, then device compactness is improved, but internal space for air channels and components is reduced
Solution Approach 1:
The wire lock is divided into distinct functional segments: the lock receiver with central conduit and slot, the piston with stem and air channel, and the compression spring. This segmentation allows each component to be optimized for its specific function while fitting within the constrained internal space of the torch housing.
Solution Approach 2:
The air channel is positioned to deliver air pressure to the piston from a direction that utilizes the available internal space efficiently. The piston moves axially within the lock receiver, utilizing the length dimension rather than requiring additional radial or lateral space, thereby maintaining compactness while accommodating the pneumatic actuation mechanism.
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 wire lock ensures consistent wire stick out distance and maintains welding accuracy by gripping the wire during robotic arm movement, enabling endless rotation without compromising welding functionality or compactness.
Implementation Method 1
The piston is reciprocally movable between an unlocked position and a locked position... utilizes pressurized air supplied through internal passageways within the welding torch
Implementation Method 2
A compression spring is positioned within the air chamber between the piston head and the lock receiver, with the compression spring configured to urge the piston toward an initial position
Data Source
AI summary
A wire lock for use with a rotary welding torch includes a piston and a lock receiver. The piston includes a head, a stem, and an air channel. The piston head defines an internal cavity in communication with the air channel. The generally cylindrical lock receiver includes a flat face, a central conduit, and a slot in communication with the central conduit. The piston and lock receiver are positioned such that the piston stem is received within the slot, respectively. The piston is reciprocally movable between an unlocked and a locked position, and the piston stem and lock receiver are configured to clamp an electrode wire therebetween when the piston is in the locked position. The wire lock may be co-axial or perpendicular to the axis of the rotary welding torch, and may be integral to the welding torch or a swan neck of the welding torch.