Welding Torch Nozzle Structure to Suppress Shield Gas Vortices
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Solution Overview
Problem
The existing welding torch designs suffer from a shortened laminar flow length of the shield gas stream, leading to vortex generation and compromised welding quality due to the configuration of the gas path within the nozzle.
Innovation Solution
A welding torch design featuring a cylindrical tip body, an orifice member with a first ring-like space, and a nozzle with a second ring-like space, where the second space is sealed by a large radius part and a tapered flow straightening wall, guiding the shield gas to extend its laminar flow length and reduce vortex generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the space inside the nozzle extends toward the torch base side, then the gas path is lengthened, but a drift including vortex is generated in the gas stream, shortening the laminar flow length
Solution Approach 1:
The nozzle space is segmented into two distinct ring-like spaces: a first ring-like space between the tip body and orifice member, and a second ring-like space between the orifice member and nozzle. This segmentation allows the gas to flow through separate zones with different flow characteristics, preventing vortex formation while maintaining adequate path length.
Solution Approach 2:
The orifice member acts as an intermediary component between the tip body and nozzle, creating the first ring-like space that mediates the gas flow. This intermediate space with its emission holes serves as a transition zone that prevents direct vortex formation in the main nozzle space.
2Productivity
If the second ring-like space is opened, then the gas path is extended, but vortex generation occurs reducing welding quality
Solution Approach 1:
The sealing part is positioned to substantially close the second ring-like space on the torch base side, creating a preliminary barrier that prevents gas from flowing backward and forming vortices. This anti-action is built into the structure to counteract the natural tendency toward vortex formation.
Solution Approach 2:
The sealing part is formed by a large radius part on the orifice member edge, using curved geometry to smoothly guide the gas flow and prevent sharp edges that would trigger vortex formation. The tapered surface with increasing radius provides smooth flow transition.
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 extended laminar flow length of the shield gas stream ensures a wider shield width at the welding target point, enhancing the welding quality by minimizing vortex-induced drift and improving gas efficiency.
Implementation Method 1
a drift including a vortex may be generated in a gas stream that is emitted from the second emission hole and moving toward the torch edge side in the space inside the nozzle
Implementation Method 2
the extended laminar flow length of the shield gas stream ensures a wider shield width at the welding target point
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A welding torch (A1) includes: a cylindrical tip body (2) extending in an axis line (Ox) direction; an orifice member (3) arranged on a radially outer side of the tip body, between which and the tip body a first ring-like space (21) is formed; a cylindrical nozzle (4) arranged on a radially outer side of the orifice member with an interposition of a second ring-like space (411) and having an edge on one side in the axis line direction. The tip body has a first emission hole (22) via which an inner space of the tip body communicates with the first ring-like space, and the orifice member has a second emission hole (34) via which the first ring-like space communicates with the second ring-like space. The second ring-like space is substantially closed by a sealing part on another side in the axis line direction, and an outlet opening (341) of the second emission hole is arranged close the sealing part (36).