Integrated Welding Cable Wire Brake for Robotic Torch Rotation
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Solution Overview
Problem
Conventional wire brakes for welding torches are separate assemblies that require additional parts and complex installations, leading to inefficiencies and increased downtime due to stress on cables and supply lines during robotic welding operations.
Innovation Solution
An integrated wire brake assembly is positioned within the welding cable, eliminating the need for a separate assembly and reducing stress on air supply lines by keeping them stationary during robotic arm rotations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate wire brake assembly is mounted on the welding torch, then the wire brake function is provided, but the device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The wire brake assembly is merged with the welding cable assembly by integrating the housing, piston assembly, and wire guide into a single unit that can be installed within the welding cable. This combination eliminates the need for separate wire brake and welding torch assemblies, reducing overall device complexity while maintaining the wire brake function.
Solution Approach 2:
The welding cable assembly is designed to serve multiple functions: it provides electrical connection, guides the welding wire, and houses the wire brake mechanism. This multi-functionality reduces the number of separate components needed in the system, simplifying both manufacturing and assembly processes.
2Reliability
If a separate wire brake assembly is mounted on the welding torch, then the wire brake function is provided, but the manufacturing precision and assembly time increase
Solution Approach 1:
The wire brake assembly is designed as a segmented, modular unit that can be independently manufactured and then installed within the welding cable. This segmentation allows for simplified manufacturing of individual components and easier assembly, reducing the precision requirements compared to integrating the wire brake directly into the welding torch.
Solution Approach 2:
The wire brake assembly is pre-assembled as a complete functional unit before installation in the welding cable. This preliminary assembly ensures proper positioning and function while simplifying the final installation process, as the entire wire brake mechanism can be installed as one unit rather than assembling multiple small components in place.
3Ease of operation
If the air supply line travels outside the robotic arm to the wire brake, then the wire brake can be positioned at the front of the welding torch, but the air supply line is subjected to stress and strain during robotic arm rotation
Solution Approach 1:
The air supply line is nested within the robotic arm structure rather than traveling externally. The wire brake assembly is positioned within the welding cable that runs through the robotic arm, allowing the air supply line to be routed internally through the arm's structure. This nesting protects the air supply line from external stress and strain during robotic arm rotation while maintaining proper wire brake positioning.
4Reliability
If conventional wire brakes are installed on the welding torch housing, then the wire brake function is provided, but additional parts and complex installation increase downtime
Solution Approach 1:
The wire brake assembly is merged with the welding cable assembly, allowing both components to be replaced as a single unit. This combination eliminates the need for separate installation procedures for the wire brake and welding cable, reducing installation time and simplifying maintenance operations.
Solution Approach 2:
The wire brake assembly is extracted from the welding torch housing and repositioned within the welding cable assembly. This extraction allows the wire brake to be accessed and replaced independently of the welding torch, significantly reducing downtime for wire brake maintenance or replacement.
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 integrated wire brake simplifies manufacturing and assembly, reduces downtime by extending the life of air supply lines, and allows for quick replacement without affecting the tool center point, thereby enhancing operational efficiency.
Implementation Method 1
a piston assembly arranged within the housing to apply a force to a welding wire
Implementation Method 2
at least one biasing device for biasing the piston
Data Source
AI summary
An example wire brake assembly for a welding torch is provided. An example wire brake assembly for a welding torch includes a housing configured to connect a welding cable to a rotating power connector for a welding torch or a welding torch neck, and a piston assembly arranged within the housing to apply a force to a welding wire. An example piston assembly includes a first end and an air inlet at a second end, a piston, a bore configured to receive the piston, at least one biasing device for biasing the piston, and an actuator arranged at the second end of the piston assembly, wherein the actuator applies a force to the welding wire in order to maintain the welding wire in a predetermined position.