Welding Electrode Coolant Suction Retraction for Spill Control
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Solution Overview
Problem
Current liquid cooling systems for welding electrodes in resistance welding machines suffer from significant coolant loss when electrodes are removed, leading to spillage, which is hazardous and inefficient, especially in high electrical current environments.
Innovation Solution
The implementation of a system that includes a drawback apparatus with a piston and chamber to actively draw back liquid coolant from the cooling paths when electrodes are partially detached, reducing or eliminating spillage by creating a suction force to retract coolant into a chamber, and utilizing independent fluid shutoff and drawback mechanisms for each electrode path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If welding electrodes are removed from the welding machine, then maintenance and replacement can be performed, but substantial liquid coolant spillage occurs which is harmful to equipment and hazardous to personnel
Solution Approach 1:
The drawback apparatus is activated before electrode removal to draw back coolant from the cooling paths and store it in a reservoir. This preliminary action prevents coolant spillage before it can occur during electrode removal, allowing maintenance to proceed safely without the harmful effect of coolant leakage.
Solution Approach 2:
A drawback apparatus acts as an intermediary between the cooling system and the external environment. This apparatus includes a piston that creates suction to draw coolant back into a reservoir, serving as a mediator that captures and contains coolant that would otherwise spill during electrode removal.
2Object-generated harmful factors
If liquid coolant flow is shut off at the source when welding electrode is lost or removed, then some spillage is reduced, but spillage still occurs from liquid already circulating in the cooling system
Solution Approach 1:
The drawback apparatus extracts coolant from the cooling paths using a piston-driven suction mechanism. This extracted coolant is drawn back into a reservoir before it can spill, effectively removing the harmful coolant from the circulation paths and preventing both spillage and unnecessary loss.
Solution Approach 2:
The system changes the pressure parameter within the cooling paths by using a piston to create negative pressure (suction). This parameter change draws coolant back into the reservoir, transforming the coolant from a state of circulation to a state of containment, thereby preventing spillage while recovering the coolant.
3Object-generated harmful factors
If a drawback apparatus with piston and chamber is used to actively draw back coolant, then coolant spillage is reduced or eliminated, but device complexity increases
Solution Approach 1:
The drawback apparatus is integrated into the existing cooling system architecture, serving multiple functions: it acts as a pump to draw back coolant, a reservoir to store the drawn-back coolant, and a control mechanism to prevent spillage. This multi-functionality reduces the need for separate components, thereby minimizing the increase in device complexity.
Solution Approach 2:
The drawback apparatus is designed to automatically activate and draw back coolant when needed, without requiring complex external control systems. The piston mechanism and reservoir work together in a self-contained manner, allowing the system to service itself by automatically preventing coolant spillage during electrode removal.
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
This solution effectively minimizes coolant loss during electrode removal, enhancing safety and operational efficiency by ensuring controlled coolant management and reducing waste, even in high-risk electrical environments.
Implementation Method 1
a first drawback element coupled to the first electrode path may be configured to drawback liquid coolant away from a gap in the first electrode path that is formed when the first welding electrode at least partially detaches. The first drawback element may include at least a piston and a chamber, the piston configured to drawback the liquid coolant away from the gap and into the chamber.
Data Source
AI summary
A first electrode coolant path is configured to cool a first welding electrode by liquid coolant flowing from a supply path through the first electrode coolant path to a return path. A second electrode coolant path is configured to cool a second welding electrode by liquid coolant flowing from the supply path through the second electrode coolant path to the return path. Three or more valves are configured to stop or reduce liquid coolant flow through the first or second electrode coolant path and configured to stop or reduce liquid coolant backflow from the return path when the first or second welding electrode is at least partially detached. At least one valve is coupled in the first or second electrode coolant path. A drawback apparatus generates a suction force to draw liquid coolant away from a gap formed when the first or second welding electrode is at least partially detached.