Weld Spatter Shield With Integrated Scraper Cleaning
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Solution Overview
Problem
Existing containment devices for splatters during billet welding in rolling lines face issues such as excessive distance between shields and billets leading to short-circuits, inefficient cleaning due to conical shapes, and complexity with multiple actuators, resulting in operational inefficiencies and increased costs.
Innovation Solution
A simplified splatter shield device with a protective shield having a rectilinear longitudinal axis, featuring a fixed cleaning device and a linearly movable protective shield, which slides along a rectilinear trajectory to protect against splatters and perform cleaning by retracting to contact the scraping tool after welding, reducing the number of components and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the protective shield is positioned close to the billet, then protection against splatters is improved, but the risk of short-circuits increases due to contact between the shield and metal
Solution Approach 1:
The protective shield is made movable along the longitudinal axis, allowing it to dynamically adjust its position between the billet and the surrounding structures. The shield can move forward during welding to provide maximum protection, and retract when not needed, eliminating continuous contact and preventing short-circuits while maintaining effective splatter protection during operation
Solution Approach 2:
The protective shield acts as an intermediary element between the billet and the surrounding equipment. By positioning the shield between these elements and allowing it to move independently, it intercepts splatters before they reach surrounding structures while preventing direct contact between the shield and billet that could cause short-circuits
2Volume of moving object
If a conical shape is used for the protective shield, then space utilization is improved, but cleaning efficiency deteriorates because the cleaning buffer cannot access the inlet area
Solution Approach 1:
The protective shield is divided into two distinct functional segments: a conical outer shell providing space-efficient containment, and a cylindrical inner cleaning surface providing accessible geometry for the cleaning buffer. This segmentation allows each segment to optimize its shape for its specific function while working together as a unified structure
Solution Approach 2:
The cylindrical cleaning surface is nested within the conical outer shell, creating a dual-geometry structure where the inner cylinder provides a cleanable surface that the buffer can access, while the outer cone maintains space efficiency and structural integrity
3Adaptability or versatility
If multiple actuators are used for shield movement and buffer operation, then functional versatility is improved, but device complexity increases
Solution Approach 1:
The single actuator is designed to perform multiple functions: it drives the protective shield's longitudinal movement for positioning, and through mechanical linkage, it also controls the cleaning buffer's engagement and retraction. This multi-functionality reduces the actuator count from multiple to one while maintaining all necessary operational capabilities
Solution Approach 2:
The actuation mechanisms for shield movement and buffer operation are merged into a single actuator system. The mechanical linkage connects the shield's linear movement with the buffer's engagement, so that one actuator simultaneously controls both functions that would traditionally require separate actuators
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 solution provides a cost-effective and efficient protection against splatters and sparks, simplifying operations by using a single actuator and reducing manual maintenance, while maintaining effective cleaning of solidified metal deposits, thus preventing short-circuits and improving system performance.
Implementation Method 1
circulating current in the billets and nearing the butts facing one another so as to create a short-circuit: the generation of heat associated therewith results in a melting of the metal
Implementation Method 2
the generation of heat associated therewith results in a melting of the metal, with resulting welding of the two ends
Implementation Method 3
a fixed cleaning device and a linearly movable protective shield, which slides along a rectilinear trajectory to protect against splatters and perform cleaning by retracting to contact the scraping tool
Data Source
AI summary
A device (100) for covering the welding area for hot rolling lines consists of an outer container (1), a protective shield (2), a blade-holder (3) with scraping blades, and an actuator (9). Protection occurs by linearly sliding the protective shield (2) outside the outer container (1) up to minimizing the gaps with the billets. The cleaning occurs at the same time as the return to the rest position: the scraping blades, which are integral with the container (1) and are installed in contact with the inner surface of the protective shield (2), slide thereon during the raising, thus colliding with the deposits of solidified material and removing them. Completing the device (100) additionally is a small alternating linear motion of the protective shield (2) during operation to always keep the attachment area of the scraping blades clean, thus avoiding the need for excessive detachment forces at the beginning of the raising.