Welding Torch Neck Adapter With Two-Piece Wire Liner Alignment
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Solution Overview
Problem
Conventional wire-fed welding torches with front-loading wire liners require time-consuming processes to change welding torch necks, as the single-piece wire liner must be fully removed and resized each time, leading to inefficiencies in adapting to different welding conditions.
Innovation Solution
A two-piece wire liner system with a welding torch neck adapter that allows the first liner segment to remain in place within the gun cable, while a separate segment is contained within the neck, enabling faster and more convenient removal and replacement of the torch neck without removing the wire liner from the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-piece wire liner is used in conventional welding torches, then the wire liner can guide the welding wire from the wire feeder to the welding torch, but the wire liner must be fully removed and resized each time the torch neck is changed, leading to time-consuming operations
Solution Approach 1:
The wire liner is divided into two separate segments: a first segment that remains in the gun cable and a second segment that is contained within the torch neck. This segmentation allows the torch neck to be changed by removing only the second liner segment, while the first segment stays in place, significantly reducing the time and effort required for torch neck changes compared to removing and resizing a single-piece liner.
2Ease of operation
If a single-piece wire liner is used, then the structure is simple, but the process of changing torch necks requires complete removal and resizing of the liner
Solution Approach 1:
The wire liner system is segmented into two parts with distinct functions: the first segment provides a stable connection in the gun cable, while the second segment allows easy removal with the torch neck. This segmentation improves ease of operation for torch neck changes while maintaining reasonable system complexity through the use of a neck adapter that facilitates the connection between segments.
3Adaptability or versatility
If the wire liner is removed from the cable when changing torch necks, then the torch can be adapted to different welding conditions, but the operation becomes more complex and time-consuming
Solution Approach 1:
By segmenting the wire liner into two parts, the system maintains adaptability to different welding conditions through torch neck changes while simplifying the operation. The first liner segment remains in the cable providing stable wiring, while the second segment is easily removed with the torch neck, eliminating the need to handle the entire liner assembly during torch changes.
Data Source
AI summary
An example welding torch neck adapter includes: an electrically conductive body configured to detachably attach to a handle assembly of a consumable electrode-fed welding torch on a first portion of the conductive body and configured to detachably attach to a neck of the welding torch on a second portion of the conductive body to secure the neck to the handle assembly; and a guide tube positioned within the conductive body and configured to support a first consumable wire liner in alignment with a liner lock of a second consumable wire liner.