Welding Gas Flow Regulation to Prevent Solenoid Valve Surge
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Solution Overview
Problem
Conventional welding-type systems experience a sudden surge of pressurized fluid when the on/off solenoid valve is reopened after a welding operation, due to residual fluid pressure, which can negatively impact subsequent operations.
Innovation Solution
Incorporating an electrically controlled proportional valve upstream of the on/off solenoid valve, which closes before the on/off valve at the end of a welding operation, allowing the pressure to equalize to ambient pressure, preventing pressure buildup and surge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an on/off solenoid valve is used to control fluid flow in welding operations, then the welding operation can be started and stopped, but a sudden surge of pressurized fluid occurs when the valve is reopened after closing
Solution Approach 1:
The flow regulator is configured to close before the on/off solenoid valve at the end of a welding operation, equalizing pressure to ambient pressure before the main valve closes. This preliminary pressure equalization prevents pressure buildup and subsequent fluid surge when the valve is reopened, while maintaining welding operation efficiency
Solution Approach 2:
The flow regulator acts as an intermediary component between the fluid supply and the welding operation. By controlling the flow rate and closing timing, it mediates the pressure transition, allowing smooth pressure equalization before the on/off valve closes, thus preventing harmful fluid surges
2Adaptability or versatility
If a manual flow regulator is used to control gas flow rate, then flow rate adjustment is possible, but manual intervention is required for each adjustment
Solution Approach 1:
The flow regulator is configured to automatically close at the end of each welding operation, equalizing pressure without requiring manual intervention. The system serves itself by automatically adjusting the flow rate and timing based on the welding cycle, eliminating the need for operators to manually adjust the regulator for each operation
Data Source
AI summary
Systems and apparatus are disclosed relating to improved fluid supply systems. In some examples, the improved fluid supply systems use an electrically controllable proportional valve and a surge prevention process to prevent a surge of pressurized fluid at the end of a welding-type operation. In particular, the surge prevention process may coordinate closure of the proportional valve and an on/off solenoid valve so that pressure in the fluid flow path can equalize to an ambient pressure after a welding operation (and/or a post flow operation) has ended. This coordination ensures that there is no pressure buildup and/or associated surge of fluid when the on/off solenoid valve is next opened (e.g., at the start of the next welding operation).