Quick-Change Welding Torch Cable Connector for TCP Stability
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Solution Overview
Problem
Conventional welding torch cable replacement is time-consuming and requires tools, disrupting the tool center point, necessitating updates to the welding program and leading to deviations from the originally programmed position.
Innovation Solution
A quick-change cable system with a housing that allows tool-free replacement of welding torch cables, utilizing a rotating power connector and fasteners like cam lobes to secure the cable without altering the tool center point, and incorporating a sealing element to reduce gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional welding torch cable replacement is performed, then the cable can be replaced, but the process is time-consuming and requires tools
Solution Approach 1:
The cable assembly is divided into modular segments including a quick-change connector, cable, and torch components. This segmentation allows the cable to be independently replaced without affecting other components, enabling rapid tool-free replacement by simply disconnecting and reconnecting the modular segments.
Solution Approach 2:
The quick-change connector incorporates dynamic elements such as spring-loaded latches and cam-actuated release mechanisms that transition between locked and unlocked states. This dynamic design enables the connector to be securely locked during operation but easily released with a simple actuating motion, eliminating the need for tools and reducing replacement time.
2Ease of repair
If conventional cable replacement is performed, then the cable can be replaced, but the tool center point is disrupted requiring welding program updates
Solution Approach 1:
The quick-change connector is pre-configured with precise mechanical features including locating pins, alignment grooves, and pre-positioned electrical contacts. This preliminary action ensures that when the cable is reconnected, all components automatically return to their original positions without requiring manual adjustment or welding program updates, maintaining the tool center point stability.
Solution Approach 2:
The connector design includes self-aligning and self-centering features that automatically position the cable and electrical contacts correctly upon reconnection. The tool center point is self-maintained through precision-machined reference surfaces and mechanical constraints that guide the components into their proper positions without external intervention or programming changes.
3Reliability
If a secure cable connection is made, then the cable is firmly attached, but the replacement process becomes more complex
Solution Approach 1:
The complex locking and sealing mechanisms are extracted and integrated into a self-contained quick-change connector assembly. This extracted design consolidates multiple functions (electrical connection, mechanical locking, sealing, and alignment) into a single modular component that maintains high reliability through integrated features while simplifying the overall replacement process through tool-free operation.
4Object-affected harmful factors
If a sealing element is added to reduce gas leakage, then gas leakage is reduced, but the device complexity increases
Solution Approach 1:
The sealing element is merged with the quick-change connector body to form an integrated sealing system. The seal is positioned within recesses and channels of the connector housing, combining the sealing function with the structural components rather than adding separate sealing mechanisms. This integration reduces gas leakage while minimizing the increase in device complexity.
Data Source
AI summary
A housing for securing a welding torch comprising a first aperture at a first end of the housing to receive a welding torch neck, a second aperture at a second end of the housing to receive a welding torch cable, and at least one fastener mounted on an external surface of the housing, wherein the fastener is configured to bias the welding torch cable toward the first aperture to secure the welding torch cable when the fastener is engaged.