Welding Device With Adjustable After-Shielding Nozzles
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Solution Overview
Problem
Welding irregular shaped plates poses a challenge as the distance of the rotation center from the outer peripheral edges varies in the circumferential direction, making it difficult to position an after-shielding nozzle effectively, which can lead to welding defects such as oxidation and scaling.
Innovation Solution
A welding device with a rotary table, a torch unit, and an after-shielding part featuring multiple nozzles that include a first nozzle upstream and a second nozzle downstream, where the second nozzle is actuated to adjust its position and orientation to maintain optimal shielding gas coverage along the irregularly shaped plates, ensuring effective antioxidant protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single after-shielding nozzle is used for welding irregular shaped plates, then the device structure is simple, but the antioxidant effect is insufficient due to varying distance from rotation center to outer peripheral edges
Solution Approach 1:
The after-shielding part is divided into multiple nozzles (first nozzle and second nozzle) arranged along the rotational direction. Each nozzle serves a specific zone of the outer peripheral edge, ensuring that shielding gas is delivered effectively regardless of the varying distance from the rotation center. This segmentation allows the system to maintain reliable antioxidant protection across the entire weld path.
Solution Approach 2:
The second nozzle is configured to be rotatable relative to the first nozzle, allowing dynamic adjustment of its orientation and position. This dynamic capability enables the nozzle to adapt to the varying curvature and distance characteristics of irregular shaped plates during rotation, optimizing shielding gas coverage without requiring a completely complex reconfigurable structure.
2Manufacturing precision
If the after-shielding nozzle is positioned at a fixed distance from the welding torch, then the device structure is simple, but the shielding gas cannot reach the outer peripheral edges effectively when the distance varies
Solution Approach 1:
Different nozzles are positioned at different locations along the rotational direction, with the second nozzle specifically positioned downstream to target areas where the outer peripheral edge is farther from the rotation center. This local differentiation ensures that shielding gas is delivered precisely where needed, achieving accurate manufacturing quality without requiring a single complex adjustable mechanism.
Solution Approach 2:
The second nozzle is made rotatable to dynamically adjust its position and orientation during the welding process. This allows the nozzle to maintain optimal alignment with the outer peripheral edge regardless of the varying distance from the rotation center, ensuring consistent shielding gas coverage without requiring continuous manual adjustment or overly complex positioning systems.
3Reliability
If multiple nozzles are arranged along the rotational direction, then the antioxidant effect is improved, but the device complexity increases
Solution Approach 1:
The after-shielding part is segmented into multiple nozzles arranged along the rotational direction, with each nozzle responsible for protecting a specific zone of the weld. This segmentation improves weld protection reliability by ensuring comprehensive coverage of the outer peripheral edge, while the modular arrangement keeps the structural complexity manageable through systematic design.
Solution Approach 2:
The multiple nozzles are integrated into a single after-shielding part that rotates together with the workpiece. This multi-functional design allows the entire after-shielding assembly to serve the entire outer peripheral edge, reducing the need for separate positioning mechanisms for each nozzle and thereby limiting the increase in overall device complexity.
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 configuration enhances the antioxidant effect of the shielding gas, reducing welding defects like scaling by ensuring consistent and improved coverage of the weld area, even with varying curvatures, thereby improving the quality of the weld.
Implementation Method 1
Immediately after welding, an after-shielding gas is jetted to a weld to shield the weld from atmosphere and prevent the weld from oxidizing while cooling the weld
Data Source
AI summary
A welding device according to some embodiments includes a rotary table fixing two irregular shaped plates which are overlapped, a torch unit including a welding torch positioned to face outer peripheral edges of the two irregular shaped plates fixed to the rotary table, a torch actuator configured to move the welding torch toward and away from the outer peripheral edges, an after-shielding part mounted to the welding torch on downstream side in a rotational direction of the rotary table and having nozzles arranged along the rotational direction, configured to jet shielding gas to the outer peripheral edges, and including a first nozzle positioned upstream and a second nozzle positioned downstream of the first nozzle in the rotational direction, and a controller configured to control an orientation of the nozzle in a direction of decreasing a shielding-gas-jetting distance between the second nozzle and the outer peripheral edges welded by the welding torch.