Segmented Welding Torch With Spring-Loaded Connector
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Solution Overview
Problem
Current welding torches require large grooves in metal shells, leading to material removal and increased filler material needs, which complicates the welding process and increases steel thickness in large cylindrical or conical structures like oil & gas platforms and wind turbines.
Innovation Solution
A block-like welding torch with parallel channels and a spring-loaded connector to maintain constant contact pressure and reduce groove dimensions, allowing for two torches to operate simultaneously, reducing material milling and filler material requirements, and enabling thinner shell designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding torches are used, then welding can be performed on metal shells, but large grooves are required leading to material removal and increased filler material needs
Solution Approach 1:
The patent changes the physical parameters of the welding torch by reducing its overall dimensions and modifying the electrode channel geometry. The channel diameter is reduced from conventional sizes to 3-8mm, and the torch body length is reduced to 50-150mm. These parameter changes enable the torch to operate in narrower grooves, reducing the amount of material that must be removed to create the groove.
Solution Approach 2:
The welding torch is segmented into multiple functional components: a body portion with electrode channels, a contact portion with contact members, and a cooling system. The contact members are further segmented into multiple individual contacts that can be independently positioned. This segmentation allows precise control of electrode positioning and contact pressure, enabling stable welding in reduced groove dimensions.
2Productivity
If conventional welding torches are used, then welding can be performed, but the torch dimensions require larger grooves and more filler material
Solution Approach 1:
The patent reduces the torch dimensions to enable operation in narrower grooves. The channel diameter is reduced to 3-8mm and the torch body length to 50-150mm. This allows the use of smaller grooves that require less filler material to complete the weld joint.
Solution Approach 2:
The contact members are designed with spring elements that provide dynamic, self-adjusting contact pressure. This ensures reliable electrical contact and stable electrode positioning throughout the welding process, maintaining productivity despite the reduced groove dimensions and smaller filler material volumes.
3Loss of substance
If groove dimensions are reduced, then material removal and filler material needs are reduced, but electrode contact stability may be compromised
Solution Approach 1:
The contact members incorporate spring elements that provide dynamic, self-adjusting contact pressure. This ensures reliable electrical contact and stable electrode positioning throughout the welding process, even in the reduced groove dimensions. The spring mechanism compensates for thermal expansion and wear, maintaining consistent contact pressure.
Solution Approach 2:
The spring-loaded contact members automatically adjust to maintain optimal contact pressure with the electrode wires without external intervention. The system self-regulates the contact force to ensure stable electrical connection and consistent electrode positioning throughout the welding operation.
4Loss of substance
If torch dimensions are reduced, then groove dimensions can be reduced, but manufacturing precision requirements increase
Solution Approach 1:
The torch is divided into modular components with precisely defined interfaces. The contact members are separately manufactured and then assembled into the body portion with precise positioning features. This modular segmentation allows high-precision manufacturing of individual components that can be assembled to achieve the required overall precision for electrode placement.
Solution Approach 2:
The patent specifies precise dimensional parameters for the torch components, including channel diameters of 3-8mm and body lengths of 50-150mm. These controlled parameters, combined with tolerance specifications, ensure that the reduced torch dimensions achieve the necessary precision for stable electrode placement in narrow grooves.
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 enables more efficient welding with reduced groove dimensions, less material removal, and accelerated welding processes, allowing for thinner shell designs and reduced steel usage while maintaining stable electrode contact and precise weld placement.
Implementation Method 1
a spring loaded device configured to hold to the elongated parts together. In this arrangement the spring loaded connector maintains a sufficient and directional constant contact pressure
Implementation Method 2
two electrode wires are fed through the welding torch and form the two electrodes between, which a welding arc can be generated for deposition of molten metal
Implementation Method 3
a welding arc can be generated for deposition of molten metal
Data Source
Figure 1~2
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AI summary
The invention relates to a welding torch for a welding device, the welding torch comprising a rectangular body provided with two parallel channels in a longitudinal direction of the rectangular body for guiding electrode wires through the body, wherein each channel has a first part at the entry side of the channel and a second part at the outlet side of the channel, the first part has a first diameter, and a second part has a second diameter, smaller than the first diameter, such that the second part tightly fits around the electrode wire for forming an electrical contact for conducting an electric welding current to electrode wire, wherein the body comprises at least two longitudinal parts, each part provided with at least one groove in the longitudinal direction for forming the channels when the parts are assembled to each other, and a spring loaded connector configured to press to the longitudinal parts together.