Welding Torch Collet System for Liner Alignment and Wear Reduction
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Solution Overview
Problem
Conventional MIG welding torches face issues with the precise positioning and securement of liners, leading to radial and longitudinal motion, causing abrasion and premature wear of components due to uncertainty in liner length and thermal expansion, and loose threaded connections resulting in efficiency losses and heat generation.
Innovation Solution
A collet system is used to radially center and secure the liner within the gooseneck or retaining head, incorporating tapered locking features and external threads to maintain axial alignment and prevent gas flow obstruction, while also enhancing threaded connections for reduced electrical resistance and heat buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the liner is secured by longitudinal pressure against the retaining head, then the liner positioning is simple, but the precise liner length required to achieve desired positioning pressure occurs only by happenstance and is thus very unlikely
Solution Approach 1:
The patent changes the parameter of liner securing from relying on longitudinal pressure alone to using radial compression force applied by the collet. This transformation allows precise positioning to be achieved through the collet's compression mechanism rather than depending on exact liner length, resolving the contradiction between manufacturing simplicity and positioning precision.
2Stability of the object's composition
If a set screw is used to secure the liner to the retaining head, then the liner movement is reduced, but the liner is not axially centered within the gooseneck or retaining head
Solution Approach 1:
The collet serves as an intermediary component between the liner and the retaining head/gooseneck. It provides both the securing function (reducing movement) and the centering function (axial alignment) that a set screw alone cannot achieve, resolving the contradiction between movement stability and centering precision.
3Device complexity
If the liner is secured by a set screw, then longitudinal termination point becomes difficult to establish and maintain, but excessive abrasion occurs as the weld wire passes through the proximal end of the liner, the gooseneck, and/or the retaining head
Solution Approach 1:
The collet acts as an intermediary that properly maintains the liner's longitudinal termination point and axial alignment. This prevents the liner from moving radially and longitudinally during operation, thereby preventing excessive abrasion of the weld wire and surrounding components while providing a more reliable securing mechanism than a set screw.
4Ease of manufacture
If threaded connections are used for attachment of welding torch components, then the components can be easily assembled, but the threaded connections tend to loosen as the welding torch is used, requiring users to stop welding to re-tighten these connections
Solution Approach 1:
The patent applies tapered locking features to the threaded connections, transforming them from static connections that loosen under vibration and heat to dynamic self-locking connections. The taper geometry creates a mechanical locking action that maintains connection stability while preserving ease of assembly and disassembly.
5Manufacturing precision
If the collet is tightened to secure the liner, then the liner position is fixed, but the gas passageway must not be blocked
Solution Approach 1:
The gas passageway is designed with local quality features - it is disposed along the exterior surface of the hollow body at a location that avoids the compression region. This allows the collet to be tightened sufficiently to fix the liner position while the gas passageway geometry ensures unobstructed gas flow, resolving the contradiction between positioning precision and gas flow path design.
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 collet system effectively minimizes wear and maintains precise alignment, extending the life of torch components, reducing downtime, and improving heat transfer and electrical conductivity by securely attaching components without blocking gas flow.
Implementation Method 1
The components of a welding torch typically have screw threads for attachment to the welding torch or other components. Unfortunately, these threaded connections tend to loosen as the welding torch is used
Implementation Method 2
The precise proximal longitudinal termination point of liner 24 generally is uncertain and not repeatable. This uncertainty results in radial and longitudinal motion of the liner 24 during torch operation, causing abrasion and premature wear of the liner 24, the retaining head 16, and other adjacent parts
Implementation Method 3
In addition, loose connections can be a source of electrical resistance that generates excessive heat within a welding torch
Data Source
AI summary
A method and apparatus for using a collet to align and/or axially secure a liner within the gooseneck of a welding torch and to extend the useful life of the torch components are provided. A method and apparatus for securing torch components including said collet and including tapered locking engagement connections are also provided. A position of the liner with respect to a retaining head or a diffuser can be established and maintained, in spite of bending, swiveling, and other general movement of the torch, while still allowing flow of a shield gas past the collet. The welding torch components, including a gas diffuser, can be secured to the torch or other torch components via tapered locking engagements. The invention is useful for both manual and robotic torch systems.