Segmented High Flow Power Cable for Welding Torch
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Solution Overview
Problem
Small welding torches require smaller, more maneuverable power cables that effectively manage heat dissipation, as conventional smaller cables face increased resistance and reduced coolant flow, leading to inadequate cooling.
Innovation Solution
A high flow power cable system with a larger diameter first segment for effective cooling and a smaller diameter second segment for maneuverability, connected by a coupler that allows for efficient fluid flow and electrical power transmission, utilizing a conduit system for both cooling fluid and electrical power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a smaller power cable is used for small welding torches, then maneuverability is improved, but resistance increases and cooling effectiveness deteriorates
Solution Approach 1:
The power cable is divided into two segments: a larger diameter first segment for effective cooling and power transmission, and a smaller diameter second segment for maneuverability. The segments are connected by a coupler that allows cooling fluid to flow between them, enabling each segment to perform its optimized function.
Solution Approach 2:
Different segments of the cable have different diameters optimized for different functions. The first segment has a larger diameter to reduce resistance and improve cooling, while the second segment has a smaller diameter to enhance maneuverability. Each segment's properties are locally optimized for its specific role.
2Volume of moving object
If a smaller power cable is used for small welding torches, then cable size is reduced, but temperature increases due to increased resistance
Solution Approach 1:
The cable is segmented into a larger first segment that handles high current with lower resistance, and a smaller second segment for precision work. The larger segment's lower resistance reduces overall power dissipation and temperature increase.
Solution Approach 2:
The cable structure varies along its length, with the first segment having larger conductor cross-section for lower resistance and the second segment having smaller cross-section. This local optimization allows the cable to maintain lower temperatures where high current flows while remaining compact overall.
3Ease of operation
If a smaller power cable is used for small welding torches, then maneuverability is improved, but coolant flow is restricted
Solution Approach 1:
The cooling system is segmented into two paths corresponding to the two cable segments. The larger first segment provides a larger coolant flow path, while the smaller second segment provides a smaller path. The coupler connects these paths, allowing sufficient total coolant flow despite the smaller second segment.
Solution Approach 2:
The coolant flow path diameter varies along the cable length, matching the conductor size in each segment. The larger first segment allows greater coolant flow to handle higher heat generation, while the smaller second segment provides adequate cooling for its lower current. This local optimization ensures sufficient cooling throughout without excessive cable size.
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 system maintains effective cooling and enhances maneuverability by reducing power dissipation in the larger diameter segment and improving heat absorption in the smaller diameter segment, thus maintaining torch performance and user control.
Implementation Method 1
power cables are often cooled by gas, water or a coolant... conducting cooling fluid through a first segment of a welding cable
Implementation Method 2
cooling fluid flows through the cable... conducting cooling fluid through a coupler... conducting cooling fluid through a second segment
Implementation Method 3
high currents may cause the power cable to increase in temperature... As the diameter of a wire decreases, its resistance increases, causing the temperature of the wire to increase
Data Source
AI summary
The invention provides a high flow power cable for a welding system designed for effective cooling of the power cable while maintaining maneuverability of the cable. Provided is a power cable having two segments, the first segment being larger in diameter than the second segment. The first segment is generally coupled to the power source and the second segment is coupled to the welding torch. The first segment includes a thicker wire, which has less resistance and dissipates less heat while the second segment includes a thinner wire, allowing for easier handling. Additionally, cooling fluid is conducted through the first segment and the second segment, further cooling the cable.