Welding Head Segmentation for Cable Mass Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding heads with magnetic arc deflection face challenges due to the rigidity and inert mass of welding-current-carrying cables, which hinder dynamic movements and complicate maintenance, especially when welding non-rotationally symmetrical components.
Innovation Solution
A welding head design featuring a mechanically connected interface device with insulated connection pieces allows for compact and efficient electrical wiring, enabling direct serial connection of additional loads and reducing the need for lengthy cables, combined with a movable mouthpiece and protective gas supply for enhanced welding characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If welding-current-carrying cables are made sturdy to handle high current intensity, then current carrying capacity is improved, but rigidity and inert mass increase which hinder dynamic movements
Solution Approach 1:
The welding head is divided into a head base and a head front end that can be separated. The holding device with the arc acting on the workpiece is located in the head front end, which can be quickly exchanged. This segmentation allows the use of lighter, more flexible cable arrangements in the movable head front end while maintaining adequate current carrying capacity through the connection interface.
Solution Approach 2:
The heavy, rigid cable system is effectively extracted from the movable portion by establishing electrical connection through the interface device at the head base. The holding device in the head front end can be supplied with current through this interface without requiring long, heavy cables to extend into the front welding region, thus enabling more dynamic movements.
2Reliability
If cables are led out from device housing into front welding region, then electrical connection is established, but device complexity and maintenance difficulty increase
Solution Approach 1:
By separating the welding head into a head base and a head front end with an interface device, the electrical connection system is segmented. The interface device provides a standardized connection point that simplifies maintenance - the head front end can be removed and replaced without complex cable disconnections, reducing maintenance difficulty while maintaining reliable electrical connection through the interface.
3Stability of the object's composition
If rigid cables are used for high current, then current stability is improved, but access to difficult welding locations is hindered
Solution Approach 1:
The segmentation of the welding head allows the head front end containing the holding device to be positioned close to the workpiece at difficult-to-access locations. The electrical connection through the interface device at the head base eliminates the need for long, rigid cables extending into the front region, thereby improving adaptability to reach various welding locations while maintaining current stability through the interface connection.
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 design simplifies the welding process by reducing cable disruptions, facilitating easier maintenance, and improving access to difficult welding locations while maintaining high welding quality through efficient current and gas delivery.
Implementation Method 1
a coil with a winding which is connected in series to the conductor of the welding current. This has the consequence that a magnetic field is formed at the same time as the welding current flows
Implementation Method 2
rapid drawn-arc method with magnetic arc deflection
Implementation Method 3
protective gas is directed onto the joining location from the side and makes oxide-free soldering possible, since the ambient air is blown away by the stream applied
Data Source
AI summary
The invention relates to a welding head for a welding device for welding components which are not rotationally symmetrical onto workpieces such as for example metal sheets, with a head attachment, the head attachment having a holding device for the component and being designed for carrying a welding current to the component, wherein the holding device is mechanically connected by means of a connecting device to an interface device, via which the welding current can be supplied, the connecting device being subdivided into a first connection piece and a second connection piece, which are electrically insulated from each other.