Midair Water Screen for Flash Butt Welding Spatter Containment
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Solution Overview
Problem
Conventional spatter collection apparatuses require frequent maintenance to remove adhering residues, as they cannot completely prevent spatter scattering during flash butt welding, leading to a troublesome cleaning process.
Innovation Solution
A spatter scattering prevention apparatus that forms a water screen in midair around the welding spot using nozzle pairs with elongated outflow ports and rectifying nozzle portions, effectively capturing and collecting spatters, reducing the need for cleaning the protective cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective cover with water layer is used to prevent spatter scattering, then spatter prevention is improved, but maintenance complexity increases due to residue accumulation on the cover
Solution Approach 1:
The invention extracts the water layer from the protective cover surface and positions it in midair as a free-standing water screen. This separation allows the water screen to be easily replenished and replaced without removing or cleaning the protective cover itself, thus solving the maintenance problem while maintaining spatter prevention effectiveness
Solution Approach 2:
The water screen acts as an intermediary barrier between the welding spot and the protective cover. By placing the water layer in midair rather than on the cover surface, it intercepts spatters before they reach the cover, preventing residue accumulation on the cover while still providing spatter protection
2Object-affected harmful factors
If a cylindrical protective cover with water injection port is used, then spatter collection is improved, but complete washing of spatters is impossible requiring manual cleaning
Solution Approach 1:
The water layer is extracted from the protective cover structure and positioned independently in midair. This allows the water screen to function as a separate, disposable element that can be easily replenished without manual cleaning of the protective cover, eliminating the cleaning complexity while maintaining spatter collection effectiveness
Solution Approach 2:
The water screen functions as a disposable or easily replaceable element. Instead of attempting to clean and reuse the protective cover, the system allows for simple replenishment of the water layer, treating it as a consumable component that eliminates the need for complex cleaning procedures
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 water screen apparatus significantly reduces the scattering of spatters, allowing them to fall and be collected, thereby simplifying maintenance by eliminating the need for frequent cleaning of adhering residues on protective covers and peripheral devices.
Implementation Method 1
configured to form a water screen in midair in the vicinity of a welding spot... wherein the water screen is for preventing spatters, generated during the welding, from scattering
Implementation Method 2
including a nozzle pair, in which each nozzle has an outflow port with an elongated shape, wherein the nozzle pair includes a first nozzle for forming the water screen on the one side and a second nozzle for forming the water screen on the other side
Data Source
AI summary
Provided is a spatter scattering prevention apparatus that eliminates the necessity to, for example, remove scattered spatters and thus makes it possible to facilitate maintenance work, and also provided is a flash butt welder including the spatter scattering prevention apparatus.The spatter scattering prevention apparatus 1 according to the present invention is characterized by being configured to form a water screen in midair in the vicinity of a welding spot, at which welding is performed, wherein the water screen is for preventing spatters, generated during the welding, from scattering.The spatter scattering prevention apparatus is also characterized by being configured to form the water screen on one side in a lateral direction of the welding spot and form the water screen on the other side, laterally opposite to the one side, of the welding spot.