Torch-Mounted Fingertip Welding Controller With Pivot Lever
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Solution Overview
Problem
Existing torch-mounted welding controllers for TIG welders require operators to alter their grip, use large finger motions, and apply significant pressure, disrupting the welding process by interfering with the precise control needed for maintaining the torch height and electrode position over the weld puddle.
Innovation Solution
A torch-mounted power controller with a control lever that allows fingertip operation, using a pivot-mounted mechanism to control welding power supply through sequential activation of switches and resistors, enabling smooth power adjustment from off to full power without altering the normal grip or requiring excessive finger motion or pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional knob or trigger controller is used, then welding power can be controlled, but large range of finger motion is required which interferes with maintaining precise torch height and electrode position
Solution Approach 1:
The control lever is segmented into a pivot point mounted in the handle and a control portion extending forward. This segmentation allows the control mechanism to be compact while providing sufficient leverage for precise power control with minimal finger motion, thereby preventing disruption of torch positioning.
2Device complexity
If friction-based control mechanisms are used, then simple construction is achieved, but significant finger pressure is required which disturbs the position of the torch electrode relative to the weld puddle
Solution Approach 1:
The patent replaces friction-based mechanical control with a pivot-mounted lever system that uses rotational mechanics. The lever pivots about a fixed point in the handle, converting finger pressure into rotational motion that actuates the power control switches. This mechanical substitution reduces the finger pressure needed compared to friction-based systems while maintaining control precision.
Data Source
AI summary
A torch-mounted power controller mounts to the handle of a welding torch and includes a control lever that is operated by the user's finger. The control lever is arranged to allow the user to hold the torch with a normal grip. Power supply to the welding torch is controlled by applying finger pressure to a control lever. A voltage control circuit is operatively connected to the control lever and controls the amount of power supplied responsive to the movement of the control lever.