Welding Gun Diffuser Sleeve for Gas Flow and Contact Tip Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for an end assembly for welding devices that allows for better control of gas flow around the weld puddle and reduces energy usage by providing consistent current flow during Metal Inert Gas (MIG) welding.
Innovation Solution
The end assembly includes a gooseneck, a diffuser sleeve, an insert, and a nozzle, where the insert and diffuser sleeve form a chamber that controls the gas flow, trapping and redirecting it to reduce contaminants and cool the contact tip, thereby improving weld quality and extending the life of the contact tip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas flow is allowed to move freely around the contact tip, then cooling effect is provided, but gas flow control and weld puddle protection are insufficient
Solution Approach 1:
The gas flow path is segmented into multiple controlled regions: an inner passage for direct cooling flow, an outer passage for protective gas flow, and a chamber that regulates the transition between them. This segmentation allows independent control of cooling gas flow and protective gas flow, resolving the contradiction between cooling effectiveness and flow control precision.
Solution Approach 2:
A chamber is introduced as an intermediary component between the inner and outer passages. This chamber receives gas from the inner passage and distributes it to the outer passage, providing a controlled transition zone that regulates gas flow patterns while maintaining both cooling and protective functions.
2Reliability
If the contact tip is securely connected to the gooseneck, then consistent current flow is achieved, but heat buildup and energy consumption increase
Solution Approach 1:
The contact tip is extracted from direct thermal contact with the gooseneck by introducing a thermal barrier layer. This layer maintains the electrical connection for consistent current flow while thermally isolating the contact tip from the gooseneck, preventing heat buildup and reducing energy consumption.
3Object-affected harmful factors
If gas flow rate is increased to improve weld puddle protection, then contaminant reduction improves, but energy consumption increases
Solution Approach 1:
Different gas flow rates and patterns are applied to different regions: high-velocity direct cooling flow in the inner passage for immediate cooling, and controlled protective flow in the outer passage for weld puddle protection. This localized quality approach optimizes gas utilization, reducing overall energy consumption while maintaining effective contaminant protection.
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 controlled gas flow reduces contaminants in the weld puddle, ensures consistent arc starts, and decreases energy consumption by maintaining a secure connection between the gooseneck, insert, and contact tip, leading to improved welding efficiency and longer contact tip durability.
Implementation Method 1
controlling the gas in the chamber to cool the insert and the contact tip
Implementation Method 2
The current produces an arc between the electrode and the workpiece. The heat of the arc melts the electrode and the workpiece
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for controlling a flow of gas in a welding device comprising the steps of : providing a gas supply, providing a welding gun (10) having a gooseneck (12) with a passageway, a diffuser connected to the gooseneck (12), the diffuser having a wall with a hole (30) and an inner passageway in fluid communication with the passageway, a diffuser sleeve (20) having a first end and a second end with an longitudinal axis extending therebetween, having a wall with a hole and having an inner cavity, the diffuser sleeve (20) connected to the gooseneck (12) with the diffuser positioned in the inner cavity and the wall of the diffuser axially adjacent and spaced apart from the wall of the diffuser sleeve (20) forming a chamber (50) positioned between the wall of the diffuser and the wall of the diffuser sleeve (20) with the hole in the wall of the diffuser sleeve (20) and the hole in the wall of the diffuser in fluid communication with the chamber (50) , a contact tip (32) configured to extend into the inner cavity of the diffuser sleeve (20), and a nozzle (36) having a gas channel (38) and configured to connect to the gooseneck (12) and extend outward along the contact tip (36), supplying the gas to the passageway of the gooseneck (12) so that the gas moves though passageway of gooseneck (12) to the inner passageway of the diffuser though the hole in the wall of the diffuser into the chamber (50), controlling the gas in the chamber (50), and controlling the gas exiting the chamber (50) through the hole (30) in the diffuser sleeve (20) and through the gas channel (38) of the nozzle (36).