Welding Wire Nozzle Block Layout for Homogeneous Process Gas Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding devices face challenges in achieving homogeneous process gas feed around the welding wire due to the technical demands and high energy costs associated with manufacturing wire feeding nozzles with boreholes, leading to suboptimal gas distribution and increased ecological and business inefficiencies.
Innovation Solution
A device with a detachable nozzle block and tube system where the process gas channel is arranged partially within the tube, featuring boreholes parallel or at an acute angle to the welding wire channel, ensuring homogeneous gas distribution by routing the gas through recesses on the nozzle block surface before exiting, thus minimizing thermal effects and optimizing gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire feeding nozzles with boreholes for process gas feeding are manufactured, then process gas can be blown concentrically around the welding wire, but the manufacture becomes technically demanding and requires multiple nozzles to be stocked, increasing costs and ecological impact
Solution Approach 1:
The patent extracts the gas distribution function from the wire feeding nozzle by providing gas channels directly in the tube wall. This separates the wire feeding function (nozzle) from the gas distribution function (tube with boreholes), making the nozzle manufacture simple while achieving homogeneous gas distribution through the tube's integrated channels.
Solution Approach 2:
The tube serves multiple functions: it guides the welding wire and simultaneously distributes process gas through its wall boreholes. This multi-functional design eliminates the need for separate gas distribution components, reducing manufacturing complexity while maintaining effective gas distribution.
2Ease of operation
If process gas is fed through heated wire feeding nozzle boreholes, then gas can reach the welding area, but the gas feed homogeneity deteriorates due to thermal effects and streams occur
Solution Approach 1:
The gas distribution function is extracted from the heated nozzle environment and relocated to the tube, which is positioned away from the direct heat source. The tube wall channels deliver gas to the nozzle area without the gas being heated in the nozzle boreholes, preventing thermal streams and maintaining homogeneity.
Solution Approach 2:
The tube wall boreholes act as an intermediary mechanism that delivers process gas close to the welding area without requiring the gas to pass through the heated nozzle boreholes. This intermediate delivery path avoids thermal contamination while still achieving effective gas distribution.
3Loss of time
If multiple wire feeding nozzles are manufactured and stocked for replacement, then down time is reduced, but manufacturing costs and energy expenditure increase
Solution Approach 1:
The gas distribution function is extracted from the replaceable nozzle and integrated into the tube, which is a permanent component. This makes the nozzle simple and inexpensive to manufacture, eliminating the need to stock multiple nozzles while maintaining rapid replacement capability.
Solution Approach 2:
The wire feeding nozzle is designed as a simple, inexpensive component without complex gas channels, making it suitable for frequent replacement or disposal. The expensive gas distribution function resides in the permanent tube, creating a cost-effective replacement strategy.
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 configuration ensures a homogeneous and efficient process gas distribution around the welding wire, reducing thermal gas streams and enhancing the quality of the welded joint while reducing manufacturing and operational costs.
Implementation Method 1
the process gas channel of the process gas feed device is arranged at least partially within the tube, and the nozzle stock is provided with several boreholes attaching it to the process gas channel
Implementation Method 2
the boreholes arranged inside the nozzle block run in recesses on the surface of the nozzle block. It is hereby achieved that the process gas can be distributed homogeneously around the nozzle block onto the wire feed nozzle even before flowing out
Implementation Method 3
minimizing thermal effects and optimizing gas flow
Data Source
AI summary
The invention relates to an apparatus for feeding welding wire and process gas to a welding device comprising a wire feeding nozzle (1), which has a welding wire channel (4), a nozzle block (2), which is releasably connected to the wire feeding nozzle (1), a profile (3), which is releasably or fixedly connected to the nozzle block (2), has a welding wire channel (6) and can be connected to a welding wire conveying device, wherein the process gas channel (9) of the process gas feeding device is arranged at least partially within the profile (3) and the nozzle block (2) is provided with multiple bores (7), which adjoin the process has channel (9) and are arranged parallel to or at an acute angel of ±5° to the welding wire chancel (4) of the wire feeding nozzle (1) and around the wire feeding nozzle (1). In this case, the nozzle block (2) is formed cylindrically in the direction of an end (14) having the wire feeding nozzle (1), wherein the bores (7) arranged within the nozzle block run out into depressions (15) on the surface of the nozzle block (2).