Twisted Fan-Shaped Insertion Element for Welding Torch Gas Lens
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Solution Overview
Problem
Existing WIG/TIG welding torches require large gas lenses with multiple filters to achieve even gas distribution across the cross-section, leading to increased size and weight, and uneven gas flow when only one filter is used.
Innovation Solution
A gas lens design incorporating a twisted, fan-shaped insertion element that causes radial deviation of the gas flow, allowing for rotation and even distribution across a smaller cavity, reducing the need for multiple filters and minimizing the size and weight of the torch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple gas-lens filters are used to achieve even gas distribution, then gas distribution uniformity is improved, but the size and weight of the gas lens increase
Solution Approach 1:
The gas lens is divided into multiple functional sections: a base body with first gas-lens filters, an insertion element with second gas-lens filters arranged in a fan-shaped pattern, and a downstream section with a third gas-lens filter. This segmentation allows each section to contribute to gas distribution, achieving uniform flow with a more compact overall structure.
Solution Approach 2:
The insertion element is inserted into the gas-distribution space of the base body, with the fan-shaped second gas-lens filters positioned within the cavity formed by the base body. This nested arrangement allows multiple filter elements to be integrated in a compact configuration, reducing the overall gas lens size while maintaining effective gas distribution.
2Manufacturing precision
If multiple gas-lens filters are used to achieve even gas distribution, then gas distribution uniformity is improved, but the length of the gas lens increases
Solution Approach 1:
The second gas-lens filters on the insertion element are arranged in a fan-shaped pattern that extends radially outward from the central bore, utilizing the radial dimension rather than only the axial dimension. This dimensional change allows the filters to be distributed more efficiently in space, achieving good gas distribution across the cross-section without proportionally increasing the axial length of the gas lens.
3Weight of stationary object
If only one gas-lens filter is used to reduce size, then the size of the gas lens is reduced, but gas distribution uniformity deteriorates
Solution Approach 1:
The insertion element features an asymmetric fan-shaped arrangement of second gas-lens filters positioned at different radial distances from the central bore. This asymmetric configuration creates varied flow paths and backflow zones that promote even gas distribution across the cross-section, compensating for the reduced number of filter elements while maintaining compact dimensions.
4Manufacturing precision
If a large cavity is provided between gas-lens filters to allow gas spread, then gas distribution uniformity is improved, but the volume of the gas lens increases
Solution Approach 1:
The design utilizes gas backflow dynamics created by the fan-shaped filter arrangement to actively distribute gas across the cavity. The specific positioning of filters at different radial distances generates pressure differentials and flow patterns that promote uniform gas distribution without requiring excessively large cavity volumes, optimizing the balance between distribution quality and compactness.
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
This design enables a 50% reduction in gas lens length, resulting in a smaller, lighter welding torch with improved handling and efficient gas distribution across the cross-section, allowing for a more compact and efficient welding process.
Implementation Method 1
fan-shaped flow elements being arranged around the bore and twisted relative to the plane of the bore so as to provide for radial deviation of a gas flowing therethrough
Implementation Method 2
This causes rotation of the gas, and allows for a better distribution of the gas
Data Source
AI summary
For a WIG/TIG welding torch, gas distribution across a cross-section of the gas lens and/or the gas nozzle, is improved and as small a size and as low a weight of the components as possible can be achieved, when an insertion element with a bore in the center through which an electrode is to be guided is arranged, with fan-shaped flow elements being positioned around the bore and twisted relative to the plane of the bore so as to provide for radial deviation of a gas flowing therethrough. The gas lens consists of a base body having a gas distribution channel with at least one gas-lens filter, with an above-described insertion element being arranged in the gas-distribution channel, and with a gas-lens filter, seen in the out-flow direction of the gas, being arranged downstream of the insertion element.