Welding Contact Fitting Segmented Arms for Wire Pressure
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Solution Overview
Problem
Existing contact fittings for powder welding struggle with uneven pressure on welding wires due to diameter differences, wire curvature, and uneven wear, leading to poor current transmission and assembly challenges, especially when trying to place multiple fittings close together.
Innovation Solution
A contact fitting design with separate elongated arms and contact shoes that are spring-loaded and movable, allowing for even pressure on both wires independently of irregularities, with guidance means like pins or plates to maintain contact and support, enabling the use of wires of different diameters and closer fitting placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common first contact shoe and common second contact shoe are used for both welding wires, then the contact fitting structure is simplified, but uneven pressure on the wires occurs due to diameter differences and wire curvature, affecting current transmission
Solution Approach 1:
The contact fitting is divided into separate contact devices for each welding wire. Each contact device includes its own first contact shoe and second contact shoe, allowing independent adjustment and even pressure distribution on each wire despite diameter differences or curvature variations.
2Ease of manufacture
If both welding wires are introduced into the contact fitting during assembly, then the contact shoes can be assembled in place, but the assembly becomes a difficult precision stage requiring correct resilience adjustment
Solution Approach 1:
The contact shoes are pre-assembled on the contact devices outside the contact fitting, allowing preliminary adjustment of resilience and positioning. This preliminary assembly simplifies the final installation into the contact fitting, avoiding difficult in-situ adjustment while ensuring correct resilience settings.
3Stability of the object's composition
If the contact fitting is designed to accommodate two wires with a fixed contact shoe arrangement, then the structure is stable, but it becomes difficult to place multiple contact fittings close to each other
Solution Approach 1:
The contact devices are arranged to extend essentially parallel to the length axis of the contact fitting rather than perpendicular to it. This orientation change reduces the width of the contact fitting in the plane defined by the wires, enabling multiple fittings to be placed close together while maintaining structural stability.
4Force
If the spring-loaded insulating pressure shoe presses the wires at a relatively large distance from the end of the contact fitting, then the contact pressure is distributed, but the welding wire may bend on the way to the welding point
Solution Approach 1:
Instead of pressing the wires at a distance from the end, the contact shoes are positioned with their second ends extending beyond or close to the second end of the housing. This reverses the conventional arrangement, providing contact pressure close to the wire exit point and preventing wire bending while maintaining even pressure distribution.
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
Ensures even pressure and stable electrical contact for both welding wires, allowing for efficient current transmission and easier assembly, enabling the use of multiple fittings in close proximity without wire bending, and allowing for the use of wires with varying diameters.
Implementation Method 1
a second contact device which is attached spring-loaded suspended in the housing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A contact fitting (1) for a welding apparatus is described. The contact fitting (1) comprises a length axis (6), a housing (7), a first contact device (32), a second contact device (33) and a third contact device (25) which is arranged between the first contact device (32) and the second contact device (33), which is movable in relation to both the first contact device (32) and the second contact device (33). The first contact device (32) has an elongated form, is arranged fixed in the housing (7) and extends from a first end (24), which is arranged between the first end (8) of the housing (7) and the second end (9) of the housing (7), to a second end (13). The second contact device (33) has an elongated form, is suspended spring-loaded to the housing (7) and extends from a first end (17), which is arranged between the first end (8) of the housing (7) and the second end (9) of the housing (7), to a second end (18).