Sealed Weld Connector Assembly for Power and Shielding Gas
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding cable assemblies are complex and cumbersome due to the large number of components required to connect welding power and shielding gas, making them difficult to construct and manage.
Innovation Solution
A welding cable connector system featuring male and female connectors with sealed passageways for gas flow, utilizing Schrader valves or preassembled valve assemblies to control gas flow, allowing for simplified construction with fewer components and efficient gas management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cables are used for power, gas, and data connections in welding systems, then each connection is reliable and dedicated, but the overall system complexity and number of components increases significantly
Solution Approach 1:
The patent combines multiple separate cable connections (power, gas, and data) into a single integrated cable assembly. The connector housing contains multiple sealed passageways for gas flow and electrical conductors for power transmission, all within one unified structure. This merging reduces the number of separate cables and connectors needed while maintaining reliable dedicated pathways for each function.
Solution Approach 2:
The integrated cable assembly serves multiple functions simultaneously: it provides electrical power transmission through conductors, shields gas flow through sealed passageways, and can include data communication capabilities. The single connector assembly replaces what would traditionally require separate cables for each function, making the system more versatile and easier to manage.
2Reliability
If multiple components are used to construct welding cable assemblies for power and gas transmission, then functional requirements are met, but construction difficulty and assembly time increase
Solution Approach 1:
The connector assembly is segmented into distinct functional zones within a unified housing: sealed passageways for gas flow are separated from electrical conductors for power transmission. Each segment performs its specific function independently while being integrated into the overall assembly, allowing for easier manufacturing and assembly compared to creating multiple separate components.
Solution Approach 2:
Multiple components that would traditionally be separate (gas sealing elements, electrical conductors, connector housing) are merged into a single integrated cable assembly. This reduces the number of assembly steps and simplifies construction while maintaining reliable gas flow control and power transmission capabilities.
3Reliability
If traditional cable assemblies with multiple components are used, then comprehensive welding support functions are provided, but operation convenience and ease of management deteriorate
Solution Approach 1:
The patent merges power transmission, gas shielding, and data communication functions into a single cable assembly, making the cable easier to manage and operate. The unified structure eliminates the need to handle multiple separate cables and connectors, improving operational convenience while maintaining all necessary welding support functions.
Solution Approach 2:
The integrated cable assembly provides universal support for multiple welding functions simultaneously - electrical power delivery, shielding gas flow, and data communication - all within one cable. This multi-functionality simplifies operation and management compared to traditional separate cable systems while ensuring complete welding 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 solution reduces the complexity and component count of welding cable assemblies, facilitating easier construction and operation while ensuring reliable gas flow control during welding processes.
Implementation Method 1
a first Schrader valve configured to stop flow of shielding gas when the male connector is not engaged
Implementation Method 2
a first sealed passageway disposed coaxially of the first conductive body for conveying shielding gas
Data Source
AI summary
An example welding cable connector system comprises: a male connector comprising a first conductive body for conveying welding power, a first sealed passageway disposed coaxially of the first conductive body for conveying shielding gas, and a first preassembled valve assembly coupled to threads within the first sealed passageway and configured to stop flow of the shielding gas when the male connector is not engaged; and a female connector comprising a second conductive body for conveying the welding power, a second sealed passageway disposed coaxially of the conductive body for conveying the shielding gas, and a second preassembled valve assembly coupled to threads within the second sealed passageway and configured to stop the flow of the shielding gas when the female connector is not engaged.