Submerged Arc Welding Torch With Resistive Wire Preheating
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Solution Overview
Problem
Existing submerged arc welding systems lack an efficient method to preheat electrode wire, which can lead to increased energy consumption and reduced efficiency in continuous welding operations.
Innovation Solution
A submerged arc welding torch and system that provides both preheating and welding current to the electrode wire using a resistive preheating mechanism, integrated into conventional torches with minimal form factor changes, utilizing copper mass to withstand welding parameters and incorporating an insulator for current path through the electrode wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional submerged arc welding systems are used without preheating, then the system structure remains simple, but energy consumption increases and welding efficiency decreases
Solution Approach 1:
The patent applies preliminary action by preheating the electrode wire before the welding arc is established. A preheating power supply provides current through the electrode wire via contact tips, raising the wire temperature to reduce the energy required for melting during welding. This preliminary heating action directly addresses the energy consumption and welding efficiency contradiction by preparing the material in advance.
Solution Approach 2:
The patent changes the temperature parameter of the electrode wire from ambient temperature to elevated temperature through resistive heating. By controlling the preheating current and duration, the system optimizes the wire temperature to achieve efficient welding with reduced arc energy requirements, thereby resolving the energy consumption versus productivity contradiction.
2Productivity
If preheating current is integrated into conventional torches, then welding efficiency improves, but device complexity increases
Solution Approach 1:
The patent implements multi-functionality by designing the submerged arc welding torch to perform both traditional welding current conduction and preheating current conduction through the same contact tips and body structure. The copper body serves both as a structural component and as a heat sink to manage thermal loads from preheating. This universal design allows one torch structure to fulfill multiple functions, minimizing the increase in device complexity while achieving preheating capability.
Solution Approach 2:
The patent merges the preheating function with the existing welding torch structure rather than adding a separate preheating device. The contact tips and copper body are utilized for both preheating current passage and welding operations, combining multiple functions into a single integrated system. This merging approach reduces the overall system complexity compared to using separate independent devices.
3Reliability
If copper mass is used to withstand welding parameters, then torch durability is maintained, but weight increases
Solution Approach 1:
The patent applies local quality by concentrating copper material specifically in the torch body where thermal management is critical, rather than uniformly distributing weight throughout the entire system. The copper mass is strategically positioned to absorb and dissipate heat from the contact tips and electrode wire during preheating and welding operations. This localized use of copper provides necessary thermal handling capability and durability while minimizing overall weight increase.
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 reduces arc energy requirements, enhances welding efficiency, and maintains the durability of the torch by using copper mass and insulators, allowing for cost-effective integration into existing systems.
Implementation Method 1
A submerged arc welding torch and system to resistively preheat electrode wire
Data Source
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AI summary
Submerged arc welding torches and systems to resistively preheat electrode wire are disclosed. A disclosed example submerged arc welding torch includes: a first contact tip configured to transfer weld current and preheating current to the wire; a second contact tip configured to conduct the preheating current to the wire; an air-cooled first conductive body portion configured to receive the weld current and to conduct the weld current and the preheating current to the first contact tip; an air-cooled second conductive body portion configured to receive the preheating current and to conduct the preheating current to the second contact tip; and an insulator coupled between the first and second conductive body portions.