Ergonomic Welding Arm with Articulated Joints for Cable Weight Support
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Solution Overview
Problem
Current welding equipment, particularly the welding cable and torch, cause excessive fatigue and inefficiency due to their weight and inflexibility, leading to unnatural postures, cable snagging, and reduced mobility, which existing counterbalance masts and trolley systems fail to fully address.
Innovation Solution
An ergonomic welding arm with multiple joints that allows for flexible movement, supporting the full weight of the cable and torch, enabling smooth tracking of the welder's movements without requiring substantial body force, and can be easily rotated and positioned to maximize reach and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the welding cable and torch are used in traditional arrangements, then the welding operation can be performed, but the welder experiences excessive fatigue due to cable weight and inflexibility
Solution Approach 1:
The patent applies counterbalance mechanisms through springs and counterweight arms that provide upward force to offset the downward force of the cable weight. The counterbalance arm with spring mechanism creates a mechanical system that automatically compensates for cable weight, reducing the force the welder must exert to hold and maneuver the torch.
2Adaptability or versatility
If the welding cable is made flexible to allow movement, then the welder can move more freely, but the cable snags on objects and breaks welds
Solution Approach 1:
The welding cable is divided into multiple segments or sections, each capable of independent movement and adjustment. This segmentation allows the cable to navigate around obstacles without snagging, as each segment can flex and adapt to the weld path while maintaining electrical connectivity throughout the length of the cable.
Solution Approach 2:
The cable system incorporates dynamic elements such as rotating joints, sliding sections, and flexible connectors that allow the cable to move smoothly and adapt to changing positions. These dynamic features prevent the cable from getting stuck or snagged on objects while maintaining reliable electrical connection during welding operations.
3Stability of the object's composition
If the wire feeder is made heavy and stationary for stability, then the welding power source is stable, but the welder must walk back and forth to change settings
Solution Approach 1:
The wire feeder is designed as a multi-functional unit that combines the welding power source, control interface, and settings adjustment mechanisms into a single integrated station. This universal design allows the welder to access and change all welding parameters at one location without needing to move between separate equipment pieces, saving time while maintaining system stability.
4Weight of moving object
If counterbalance masts are used to support cable weight, then some weight is lifted, but the masts are stiff and only rotate in the center, limiting welder movement
Solution Approach 1:
The counterbalance mast system is replaced with dynamic, multi-axis articulating arms that can rotate and flex at multiple joints along their length. These articulated arms provide cable weight support through integrated counterbalance mechanisms while allowing the welder to move freely in multiple directions, eliminating the rotational limitations of fixed-center masts.
Data Source
AI summary
An ergonomic welding arm (1) includes a plurality of arm links (14, 20, 24) coupled by a plurality of joints (12, 18, 22). Each of the plurality of joints (12, 18, 22) is configured to allow the plurality of arm links (14, 20, 24) to be rotated about an axis with respect to a directly adjacent arm link (14, 20, 24). A first end of the welding arm (1) is configured to engage a support (4) for supporting the welding arm (1). A second end of the welding arm (1) is configured to engage a welding torch (10).