Segmented Welding Wire Liner with Swivel Joints
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Solution Overview
Problem
Existing welding wire guiding systems face issues such as attrition, wire surface contamination, deformation, and excessive friction, leading to inconsistent wire feeding and potential torch tip damage, especially when used with modern multiple-axis welding robots that require flexible rotational movements.
Innovation Solution
A welding wire guiding liner composed of multiple guiding bodies connected by swivel joints and freely rotatable rings, allowing for smooth articulation and rotation without building up torsional loads, featuring a simple mechanical design with connecting lugs and elastic rings for secure assembly and tension relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If welding wire is fed over large distances through a liner, then the wire can reach the welding torch from bulk containers, but attrition occurs causing intermittent and inconsistent wire feeding
Solution Approach 1:
The liner is divided into multiple separate guiding bodies (at least two) connected by swivel joints. Each guiding body contains rolling elements that independently guide the wire, allowing the segmented structure to reduce attrition while maintaining long-distance feeding capability
Solution Approach 2:
Rolling elements are introduced as intermediary components between the wire and the liner walls. These rolling elements guide the wire through the liner with minimal friction and attrition, enabling reliable wire feeding over large distances
2Productivity
If welding wire is fed through a liner at high speed, then productivity increases, but wire surface contamination accumulates in the liner
Solution Approach 1:
The liner is segmented into multiple guiding bodies connected by swivel joints, creating discrete sections that prevent contamination accumulation. Each segment can be independently maintained or replaced, reducing the overall contamination problem in long-distance wire feeding
3Manufacturing precision
If the liner is made rigid to maintain wire guidance precision, then manufacturing precision improves, but the liner cannot accommodate rotational movements of modern multiple-axis welding robots
Solution Approach 1:
The liner transitions from a rigid structure to a dynamic articulated structure with swivel joints between guiding bodies. Each joint allows rotational movement to accommodate welding robot motions while the rolling elements within each body maintain precise wire guidance
Solution Approach 2:
The liner is divided into multiple independent guiding bodies that can rotate relative to each other via swivel joints. This segmentation allows the liner to adapt to complex robotic movements while each individual body maintains precise wire guidance through its rolling elements
4Adaptability or versatility
If swivel connections are added at discrete intervals to discharge tension from robot movements, then adaptability improves, but each connection forms an interruption of the guiding liner
Solution Approach 1:
The swivel joint functionality is merged with the guiding body structure itself. Each guiding body incorporates swivel joints as integral parts, allowing rotational movement without creating separate interruptions in the guiding path. The rolling elements continue to guide the wire smoothly through each articulation point
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 ensures reliable, low-friction wire guidance, preventing deformation and contamination while enabling continuous operation with modern welding robots, reducing the risk of liner breakage and maintaining consistent weld quality.
Implementation Method 1
Each guiding body comprises a set of rolling elements which guide the welding wire without friction
Implementation Method 2
The ring is connected to the adjacent guiding body by means of a swivel joint which allows the adjacent guiding body to swivel around a swivel axis with respect to the guiding body provided with the ring
Implementation Method 3
featuring a simple mechanical design with connecting lugs and elastic rings for secure assembly and tension relief
Data Source
Figure 1
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Figure 5~9
AI summary
A welding wire guiding liner has a plurality of guiding bodies (10) connected to each other, each of the guiding bodies (10) containing a plurality of rolling elements defining a guiding channel for the welding wire. Each guiding body (10) has a ring which is coaxial with the guiding channel and is freely rotatable in a peripheral direction on the body. The ring is connected to the adjacent guiding body (10) by means of a swivel joint which allows the adjacent guiding body (10) to swivel around a swivel axis with respect to the guiding body (10) provided with the ring.