Welding Power Source Housing Layout for Low-Collision Cable Connection
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Solution Overview
Problem
Existing welding power sources have pole contact devices that protrude from the housing, causing space inefficiencies and increased risk of collisions with cables, which is problematic in industrial environments where multiple welding production cells are used.
Innovation Solution
The pole contact devices are positioned entirely within the housing's projection surface, with a detachable connection mechanism using a rotational movement, and the cables are routed internally or rearward to minimize protrusion and collision risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pole contact devices protrude from the housing, then accessibility for cable connection is improved, but the space required and collision risk increase
Solution Approach 1:
The pole contact devices are oriented at an angle (e.g., 45 degrees) relative to the housing surface, transitioning from a purely protruding design to a multi-dimensional configuration. This angular orientation allows cables to be connected while reducing the horizontal footprint and minimizing collision risk with surrounding equipment.
Solution Approach 2:
Instead of having the pole contact devices extend outward from the housing, the design inverts the approach by integrating them within the housing boundary while providing angled access points. This inversion maintains electrical connection functionality while eliminating the space-consuming protrusion.
2Ease of operation
If pole contact devices protrude from the housing, then cable connection is facilitated, but the risk of collisions with cables increases
Solution Approach 1:
By orienting the pole contact devices at an angle rather than extending them perpendicularly outward, the design creates a three-dimensional configuration that reduces the horizontal projection. This minimizes the likelihood of cables colliding with the contact devices while maintaining accessible connection points.
Solution Approach 2:
The pole contact devices are nested within the housing boundary rather than extending beyond it. The angled orientation allows the contact devices to be contained within the housing's external dimensions, effectively nesting them to reduce collision risk with surrounding cables and equipment.
3Area of stationary object
If pole contact devices are positioned within the housing projection surface, then space utilization is improved, but accessibility for connection may be reduced
Solution Approach 1:
The pole contact devices are positioned within the housing projection surface but oriented at an angle to the surface. This angular configuration provides connection accessibility from the side or above rather than from the front, maintaining ease of operation while achieving compact space utilization.
Solution Approach 2:
The pole contact devices use asymmetric angular orientation rather than symmetric perpendicular protrusion. This asymmetric design allows one end to be accessible for connection while the other end remains within the housing boundary, optimizing both accessibility and space utilization.
Data Source
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AI summary
The invention relates to a welding current source (1) for supplying an arc welding torch with electric current and electric voltage for carrying out an arc welding method, wherein the arc welding current source is provided with a housing (4), in which a current transformer device is provided for processing electric current and voltage fed into the welding current source (1) for suitability in an arc welding method, wherein furthermore two pole contact devices (5, 6) are provided on the housing (4) of the welding current source (1), each of which protrudes out of the housing (4) along a respective longitudinal axis and is provided with connecting means for receiving a welding current cable. The aim is to provide a possibility that collisions with welding power cables (3) connected to a welding current source (1) of the aforementioned type can be avoided as much as possible. For this purpose, it is proposed that at least one of the two pole contact devices (5, 6) is located completely within a projection surface of the housing (4) on a plane, in which a mounting surface of the welding current source (1) is located, wherein the projection takes place along an axis running perpendicular to the mounting surface.