Welding Torch Cleaning via Pneumatic Abrasive Jet
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Solution Overview
Problem
Existing methods for removing welding spatter from welding torches often damage the inner surfaces and introduce moisture, leading to impaired weld seam quality due to temperature differences and abrasive condensation.
Innovation Solution
A device using a granular abrasive, such as small-grained corundum, is blown into the welding torch head with high-pressure compressed air and a rotating/pivoting movement to knock off spatter without damaging the gas nozzle or contact tip, utilizing a motor-controlled jet nozzle and suction system to collect and recycle the abrasive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting tools (milling cutters) are used to remove welding spatter, then spatter removal is achieved, but the inner surfaces of the gas nozzle, contact tip and insulating parts are damaged
Solution Approach 1:
The patent replaces the mechanical cutting tools (milling cutters) with a jet blasting system that uses high-velocity abrasive particles carried by compressed air. This substitution eliminates direct mechanical contact between cutting tools and the torch surfaces, thereby preventing damage to inner surfaces while still achieving effective spatter removal through kinetic impact of the abrasive grains
Solution Approach 2:
The invention employs a pneumatic jet blasting system where compressed air serves as the carrier medium to transport granular abrasive (such as corundum) into the welding torch head. The high-velocity air stream propels the abrasive particles to knock off adhering spatter, providing a non-contact cleaning method that avoids surface damage while maintaining cleaning effectiveness
2Manufacturing precision
If cold blasting agents (dry ice, carbon dioxide snow) are used with temperature difference > 80 K, then cleaning effect is improved, but condensation problems and moisture introduction occur leading to impaired weld seam quality
Solution Approach 1:
The patent changes the temperature parameter of the blasting agent from cold (dry ice at -78.5°C) to ambient or warm temperature compressed air. This parameter change eliminates the temperature difference that causes condensation, while maintaining effective cleaning through the kinetic energy of the high-velocity abrasive particles propelled by the compressed air stream
3Productivity
If milling cutters rotate to scrape off impurities, then spatter removal is achieved, but the contact tip and insulating parts are damaged
Solution Approach 1:
The patent replaces the rotating mechanical milling cutters with a stationary jet nozzle that directs high-velocity abrasive particles at the spatter. This substitution maintains high productivity through the kinetic energy of the abrasive stream while eliminating mechanical contact that would damage the contact tip and insulating parts
Solution Approach 2:
The compressed air stream serves as an intermediary medium that transfers kinetic energy to the abrasive particles, which then impact the spatter for removal. This intermediary approach allows effective spatter removal without requiring direct mechanical contact between rotating tools and the torch components
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
Effectively removes spatter and contaminants while polishing the surfaces, preventing re-adhesion without additional anti-adhesive agents, maintaining weld quality and extending the torch's operational life.
Implementation Method 1
The kinetic energy of the granular abrasive is so great that adhering weld spatter is knocked off
Implementation Method 2
A jet nozzle (4) which is moved rotating and/or pivoting about an imaginary axis by a holder (6)... An injector (5) for the metered supply of compressed air is arranged on the jet nozzle (4)
Implementation Method 3
The granular abrasive carried by the compressed air, e.g. B. small-grained corundum, is blown with pressure and the supporting movement into the welding torch head and knocks off the adhering spatter or other impurities. At the same time, the inner surface of the welding torch head is blasted bright
Implementation Method 4
When the welding torch is inserted into the safety hatch, a seal wraps around the opening in the safety hatch, ensuring a positive fit
Implementation Method 5
The granular abrasive suction pipe connected to the injector is connected to the granular abrasive storage tank on the other side
Implementation Method 6
Through the hopper, the contaminants and unused abrasive grit fall onto a screen through which the abrasive grit falls back into the hopper and the contaminants are removed from the system by the screen
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for removing welding spatter from welding and cutting torches without damaging the welding or cutting torch on the cleaned surface. It is essential for the invention that a granular abrasive is blown into the welding or cutting torch from below under pressure and with a rotating and/or pivoting motion and that the kinetic energy of the granular abrasive is adequate to knock off the welding spatter. A further advantageous effect of the method is that the cleaned surface is at the same time polished, and consequently renewed attachment of welding spatter is delayed. A specially designed device for carrying out the method is described. The device for carrying out the method for removing welding spatter from welding and cutting torches is transportable and is suitable in particular for cleaning gas metal arc welding torches and gas metal arc cutting torches.