Compact Welding Apparatus Using Guide Surface and Ring Gears
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Solution Overview
Problem
Conventional welding apparatuses for cylindrical pipes are cumbersome due to the need for pre-winding power supply wires and complex control systems, leading to increased size, weight, and manufacturing costs.
Innovation Solution
A compact and lightweight welding apparatus design featuring a housing with a guide surface, ring gears, and electric motors that transmit torque to a welding head, eliminating the need for large rollers and reducing the number of gears, with a differential device to simplify motor control and eliminate the ball screw mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the welding apparatus uses a ball screw mechanism to move the housing forward and backward, then the housing can be positioned accurately, but the apparatus increases in size and weight
Solution Approach 1:
The patent removes the ball screw mechanism from the apparatus, extracting the heavy positioning component while maintaining positioning capability through the guide surface and roller system. This extraction directly reduces the apparatus weight and size while preserving the necessary positioning function.
2Strength
If the welding apparatus uses multiple rollers to support high-rigidity disc plate gears, then the gears maintain high rigidity, but the apparatus increases in size
Solution Approach 1:
The patent eliminates the large disc plate gears and their supporting rollers, removing the bulky mechanical transmission system. Instead, it uses a compact differential device with electric motors that achieves the same functional outcomes (wire feeding, torch movement) without requiring large rigid gears, thereby reducing the apparatus footprint.
3Manufacturing precision
If the welding apparatus controls the rotating speed of each electric motor separately, then the wire feeding and torch movement can be precisely controlled, but the control device structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent merges the control functions into a centralized differential device that coordinates the electric motors. Instead of separate control systems for each motor, the differential device integrates the control logic, reducing the overall control system complexity while maintaining precise control over wire feeding and torch movement through the mechanical differential mechanism.
4Strength
If the welding apparatus uses internal and external teeth on the entire circumference of the gear periphery, then the gear engagement is robust, but the manufacturing process requires many steps
Solution Approach 1:
The patent removes the complex full-circumference internal and external gear teeth configuration. Instead, it uses a simplified gear arrangement where teeth are provided only in specific regions necessary for the differential mechanism to function, reducing manufacturing steps while maintaining sufficient engagement strength for the application.
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 results in a more compact, lightweight, and cost-effective welding apparatus that simplifies motor control and reduces manufacturing complexity, enabling efficient welding operations without pre-winding power supply wires.
Implementation Method 1
a guide member (R) that supports the welding head turning gear (40) and the ring gear (50, 60, 70) to rotate along a guide surface (11a)
Implementation Method 2
a plurality of electric motors (M1 to M4) that transmits torque to the turning input gear (42) and the ring input gears (52, 62, 72)
Implementation Method 3
a welding head turning gear (40), at least one ring gear (50, 60, 70) in annular shape, a turning input gear (42) and ring input gears (52, 62, 72)
Data Source
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AI summary
To provide a light-weight and compact welding apparatus. The welding apparatus 10 includes a housing 12 having facing surfaces 13, 13 in the axial direction, and a welding head turning gear 40 and first to third ring gears 50, 60, 70 inside of the housing 12. A guide surface 11a is formed on the facing surfaces 13, 13. The welding head turning gear 40 is coupled to a guide member 41, and the first to third ring gears 50, 60, 70 are supported by the welding head turning gear 40 and the guide member 41. Since a roller provided to the guide member 41 rolls on the guide surface 11a to rotatably support the first to third ring gears 50, 60, 70 with respect to the housing 12, the welding apparatus 10 can be lighter in weight and more compact compared to a conventional welding apparatus.