Welding Connector Sealed Gas Passageway
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Solution Overview
Problem
Manual welding operations face challenges in managing multiple cables for power, gas, and data transmission, leading to complexity and inefficiency in welding systems.
Innovation Solution
A welding cable connector system with male and female connectors that integrate power and shielding gas transmission, featuring sealed passageways and gas sealing valves to prevent gas flow when not engaged, reducing the number of cables required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate cables are used for power, gas, and data transmission in welding systems, then each function can be transmitted reliably, but the system becomes complex and difficult to manage
Solution Approach 1:
The patent combines multiple separate cables for power, gas, and data transmission into a single integrated connector assembly. The connector housing contains separate sealed chambers for each function (power contacts, gas passages, data connections) that are mechanically and electrically isolated yet integrated within one unit, eliminating the need to manage multiple separate cables while maintaining reliable transmission of all functions.
2Productivity
If gas flow is allowed through open connectors, then gas can be transmitted during welding operations, but gas leaks occur when connectors are not engaged
Solution Approach 1:
The connector incorporates automatic gas sealing valves that are pre-positioned to seal the gas passages when the connector is not engaged. These valves are spring-loaded or elastomeric mechanisms that automatically close the gas flow path upon disconnection, preventing gas leaks before they can occur. When the connector is engaged, the mating connector actuates these valves to open the gas flow path for welding operations.
3Device complexity
If connectors are designed with integrated power and gas transmission, then cable management is simplified, but ensuring sealed gas flow becomes more difficult
Solution Approach 1:
The integrated connector is segmented into separate sealed chambers for power and gas transmission. Each chamber has its own sealing mechanism and flow control features. The gas chamber contains dedicated sealing surfaces and valve mechanisms that are independently designed and manufactured, allowing precise control of gas flow sealing without compromising the integrated design benefits.
4Object-generated harmful factors
If gas sealing valves are added to prevent leaks, then gas flow is controlled when not engaged, but the connector structure becomes more complex
Solution Approach 1:
The gas sealing valves are designed as self-actuating mechanisms that automatically open or close based on the engagement state of the connector. Spring-loaded elastomeric seals or poppet valves use the mechanical action of connector engagement/disengagement to control gas flow without requiring external control systems, maintaining relatively simple structure while effectively preventing gas leaks.
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 simplifies cable management by combining gas and power into a single cable, enhancing operational efficiency and reducing clutter in welding systems while maintaining effective gas and power delivery during welding operations.
Implementation Method 1
a gas sealing valve configured to seal the passage to stop gas flow when the connector is not engaged with the mating connector
Data Source
AI summary
A weld electrical and gas connector with sealed gas flow is provided. In an exemplary embodiment, a welding cable connector system includes a male connector having a conductive body for conveying welding power. The male connector includes a sealed passageway disposed coaxially of the conductive body for conveying shielding gas, and a gas sealing valve configured to seat to stop flow of shielding gas when the male connector is not engaged. The system also includes a female connector having a conductive body for conveying welding power. The female connector includes a sealed passageway disposed coaxially of the conductive body for conveying shielding gas, and a gas sealing valve configured to seat to stop flow of shielding gas when the female connector is not engaged. The male and female connectors are mutually engageable to conduct welding power and shielding gas therethrough.