Integrated Welding Power Connector With Hidden Coolant Routing
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Solution Overview
Problem
Conventional power supplies require separate connections for coolant hoses, shielding gas, and welding power, leading to complexity and inefficiency in manufacturing and customer experience.
Innovation Solution
A power supply connector that integrates coolant, shielding gas, and welding power into a single unit, with a coolant path hidden within a bezel to prevent leakage and reduce connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connections are used for coolant hoses, shielding gas, and welding power, then each connection can be independently connected, but the device complexity and manufacturing complexity increase significantly
Solution Approach 1:
The patent combines multiple separate connections (coolant inlet, coolant outlet, shielding gas, and welding power) into a single integrated connector. This single connector includes all necessary connection points and routing paths, allowing all connections to be made at one location rather than requiring multiple separate connection points on the power supply and cooler.
2Ease of manufacture
If separate connections are used for coolant hoses, shielding gas, and welding power, then each component can be independently manufactured, but the manufacturing complexity increases
Solution Approach 1:
The connector integrates multiple functions (coolant routing, gas supply, and power connection) into a single manufactured component. This allows the connector to be produced as one unified part rather than requiring the assembly of multiple separate components, thereby reducing manufacturing complexity while maintaining component independence for the overall system.
3Ease of manufacture
If coolant path is external to the power supply, then coolant routing is simple, but coolant may ingress into the power supply causing harmful effects
Solution Approach 1:
The coolant routing paths are nested within the structure of the single connector itself. The connector includes internal passages and routing paths that guide coolant from the inlet to the outlet while keeping the coolant contained within the connector's structure, preventing any possibility of coolant ingress into the power supply while maintaining routing simplicity.
4Ease of operation
If multiple connection points are required on power supply and cooler, then flexible connection is possible, but the ease of operation decreases
Solution Approach 1:
The patent merges all connection functions into a single connector that provides all necessary connections (coolant inlet, coolant outlet, shielding gas, and welding power) at one location on both the power supply and cooler. This eliminates the need for multiple separate connection points, significantly improving ease of operation by reducing the number of connection steps required.
Data Source
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AI summary
According to the present disclosure, a welding-type system (200) includes a cooler (120) configured to recirculate coolant from a welding-type tool (140) and comprises a cooler connection (126), a power supply (110) comprising power conversion circuitry configured to convert input power to welding-type power, and a bezel (112) comprising a power supply connector (116) and configured to provide a coolant path between the power supply connector (116) and the cooler connection (126). Further, a welding welding-type power supply connector (116) includes a gas connection configured to receive shielding gas, an outlet connection configured to provide coolant to a welding-type tool (140), and an inlet connection configured to receive the coolant from the welding-type tool (140), wherein the power supply connector (116) provides welding-type power.