Torch Feed Roll Adjustment Lever for Hands-Free Wire Threading
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Solution Overview
Problem
Welding torches face challenges with consumable weld wire threading due to manual operation requirements, inadvertent adjustment of wire feed controls, and thermal issues, leading to inefficiencies and operator fatigue.
Innovation Solution
A torch assembly with a wire feeder system featuring securable feed rolls and a lever for hands-free operation, a feed control resistant to inadvertent adjustments, and a barrel assembly with thermal separation to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cam is used to separate the rolls during threading, then the rolls can be separated to allow wire passage, but the operator must maintain constant hand contact with the cam, requiring one hand to be occupied throughout the threading process
Solution Approach 1:
The lever is spring-biased to automatically return to the separated position after being actuated, allowing the rolls to self-separate without requiring the operator to continuously hold the cam. This self-service mechanism frees the operator's hand while maintaining roll separation.
Solution Approach 2:
The lever transitions from a static cam requirement to a dynamic, momentary actuation system. The lever can be quickly pushed to engage the rolls for threading, then automatically returns to the separated position, creating a dynamic operation that is faster and more efficient than constant cam holding.
2Ease of operation
If the rolls are kept in the separated position during threading, then the wire can be passed through, but the operator cannot use both hands to manipulate the weld cable or make adjustments to other components
Solution Approach 1:
The spring-biased lever automatically maintains the rolls in the separated position and returns to this position after actuation, allowing the operator to use both hands for cable manipulation and adjustments without needing to continuously hold the lever.
Solution Approach 2:
The lever is designed to be actuated only momentarily to achieve the desired roll engagement, then automatically returns to the separated position. This preliminary action approach allows the operator to prepare the rolls for threading and then freely manipulate other components without constraint.
3Reliability
If the operator repeatedly opens and closes the rolls during threading to free stuck wire, then the threading process can continue, but the process becomes time-consuming and frustrating
Solution Approach 1:
The lever provides quick, easy actuation for engaging and disengaging the rolls. The spring bias ensures rapid return to the separated position, allowing the operator to quickly open and close the rolls if wire becomes stuck, maintaining reliability while minimizing time loss.
Solution Approach 2:
The automatic return mechanism allows the operator to focus on wire manipulation rather than lever control. The lever self-returns to the open position, enabling rapid repeated cycling of the rolls if needed to free stuck wire without the overhead of manual lever control.
4Ease of operation
If wire feed control is mounted on the torch for convenient operator access, then the operator can adjust wire feed speed without returning to the power source, but the control is subject to inadvertent adjustment from torch impacts and manipulation
Solution Approach 1:
The control mechanism is designed with features that prevent inadvertent adjustment before impacts or manipulation can occur. This might include detent mechanisms, friction locks, or geometric constraints that require deliberate, sustained operator input to change settings, thereby counteracting the harmful effect of accidental contact.
5Strength
If the torch is constructed to withstand impacts and manipulation, then it can be used in demanding welding environments, but thermal management becomes more challenging due to added mass and structural complexity
Solution Approach 1:
The torch is divided into modular sections with thermal management systems integrated into each. This segmentation allows for efficient heat dissipation in each section while maintaining the overall structural durability needed to withstand impacts and manipulation in demanding welding environments.
Data Source
Figure 1
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AI summary
A torch and a welder having a torch constructed to pull a consumable weld wire (72) thereto are disclosed. The torch includes a wire feeder assembly (66) having a first feed roll (68) and a second feed roll (70). Operation of the feed rolls pulls a consumable weld wire to the torch. A lever (76) selectively separates the first and the second feed rolls and is securable to allow a hands-free separation of the feed rolls.