Handheld Welding Rod Holder with Automatic Feed Mechanism
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Solution Overview
Problem
Conventional arc welding processes are ergonomically awkward due to the user holding the welding rod at a distance from the welding site, leading to inconsistent and low-quality welds as the rod shortens, requiring frequent adjustments and unnatural hand positioning.
Innovation Solution
A hand-held welding rod holder with an integral arc welding lead contact and automatic feed mechanism, allowing the user to maintain a consistent distance and comfortable grip near the welding site, featuring a biasing mechanism for controlled rod ejection and a finger brake for manual override, enabling ergonomic operation and precise weld placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the welding rod is held using a clamp at the opposite end from the welding process, then the user can maintain control of the welding rod, but the ergonomic quality deteriorates and weld consistency decreases
Solution Approach 1:
The patent combines the rod holding function, electrical contact function, and automatic feed mechanism into a single integrated rod holder assembly. The clamp body houses both the electrical contact tip and the biasing mechanism, merging multiple functions into one device that improves ergonomics while maintaining control.
Solution Approach 2:
The biasing mechanism automatically feeds the welding rod forward as it is consumed during welding, eliminating the need for manual rod replacement or adjustment. The spring-loaded system self-regulates to maintain consistent rod extension, improving ergonomic quality without requiring complex external feed systems.
2Manufacturing precision
If the welding rod length varies during the welding process, then the rod can be continuously fed, but the distance consistency from the work area deteriorates
Solution Approach 1:
The rod holder employs a dynamic biasing mechanism with a spring-loaded clamp that automatically adjusts to maintain a consistent distance between the rod end and the work area. As the rod is consumed, the spring mechanism dynamically feeds forward the appropriate length to maintain positioning precision throughout the welding process.
3Productivity
If the user manually adjusts the welding rod frequently, then the rod can be replaced when exhausted, but the welding process efficiency decreases
Solution Approach 1:
The automatic feed mechanism continuously supplies welding rod as it is consumed, eliminating the need for frequent manual interruptions to replace or adjust the rod. The spring-loaded system self-regulates rod feed rate to match consumption rate, significantly improving welding efficiency by removing repetitive manual adjustment tasks.
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
Enhances user comfort and weld quality by maintaining a consistent distance between the welding rod and the work area, allowing for more accurate and natural welding movements, similar to drawing with a pencil, while automatically feeding the welding rod as needed.
Implementation Method 1
The biasing mechanism is configured to move the welding rod out of a lower end of the body
Data Source
AI summary
According to an embodiment of the disclosure, a welding rod holder comprises a body, an electrical contact tip, a slider, and a biasing mechanism. The body has a lower end and an upper end. The electrical contact tip is coupled to the body and is configured to electrically contact a welding rod. The slider is configured to allow the welding rod to move with respect to the body. The biasing mechanism is configured to move the welding rod out of a lower end of the body. The hand brake is configured to selectively allow the biasing mechanism to move the welding rod out of a lower end of the body. The movement of the welding rod out of a lower end of the body is configured to allow a substantially similar distance between the body and a welding work as the welding rod is exhausted.