Leaf-Spring Welding Tip With Wear Particle Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing contact tips in arc welding experience wear particle deposition, which reduces the pressing force on the welding wire, leading to fluctuations in current feed and a shorter service life due to the accumulation of wear particles on the leaf spring, causing uneven wear and potential welding defects.
Innovation Solution
A welding tip design with a wire insertion bore and a pressing part that includes a first aperture for the leaf spring and a second aperture for discharging wear particles externally, ensuring the pressing force is maintained and preventing wear particle accumulation, while an insulator and a separate feeding member can further enhance stability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a leaf spring is used to press the welding wire onto the contact tip, then current feed stability is improved, but wear particles accumulate on the leaf spring causing pressing force reduction and service life shortening
Solution Approach 1:
The patent extracts the harmful wear particles from the contact tip interior by providing a discharge path (opening in the side wall of the contact tip body) that leads to the exterior. This allows wear particles to be removed from the system rather than accumulating on the leaf spring, thereby maintaining pressing force and extending service life while preserving current feed stability.
2Ease of operation
If the wire insertion bore becomes large due to wear, then wire insertion ease is improved, but wire positioning accuracy deteriorates causing contact area variation
Solution Approach 1:
The patent employs a leaf spring as a dynamic pressing mechanism that continuously applies force to the welding wire, maintaining consistent contact pressure despite wear of the wire insertion bore. The leaf spring's elasticity allows it to compensate for bore enlargement, ensuring stable wire positioning and contact area while still allowing easy wire insertion.
3Reliability
If sparks are produced between welding wire and wire insertion bore, then electrical connection is established, but inner surface unevenness increases causing frictional resistance and wire feed issues
Solution Approach 1:
The patent converts the harmful effect of spark-generated wear particles by providing a dedicated discharge path. Instead of allowing particles to accumulate and increase friction, the opening enables particles to be expelled from the contact tip, transforming a harmful accumulation process into a controlled removal mechanism that maintains smooth wire feed while preserving necessary electrical connection through sparks.
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
The design effectively discharges wear particles, maintaining the pressing force on the welding wire, increasing the service life of the welding tip and ensuring stable current feed, reducing frictional resistance, and preventing welding defects.
Implementation Method 1
The leaf spring has a front end embedded in the contact tip, a rear end inserted in a recess disposed in communication with the aperture, and a center protruding portion extending in the aperture to protrude into the wire insertion bore. The center protruding portion of the leaf spring is energized to press the welding wire onto the inner surface of the wire insertion bore.
Implementation Method 2
a welding current is supplied to the welding wire from a welding machine via a contact tip, which is a welding tip, disposed at the distal end of the welding torch
Data Source
AI summary
A welding tip includes a tip body having a wire insertion bore along a central axis and a leaf spring configured to press a welding wire onto a feeding point disposed on an inner surface of the wire insertion bore. The tip body 1a has an aperture on an outer circumferential surface on the distal end side. The leaf spring has a first end that is a free end disposed on the distal end side of the tip body and a second end fixed to the tip body. The aperture includes a first aperture accommodating the leaf spring and second apertures disposed in communication with the first aperture and configured to discharge wear particles created during welding to the outside.