Orbital Welding Torch Lead-Lag Angle Stop Mechanism
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Solution Overview
Problem
Existing orbital welding systems lack a simple and efficient method for accurately and repeatably setting and resetting the lead or lag angle of a welding torch, particularly in industrial applications involving curved surfaces, leading to inconsistencies and inefficiencies in the welding process.
Innovation Solution
A system comprising a torch adapter with a shaft sleeve, an adjustment shaft, a lead-lag coupler, and a rotatable stop set with a stop pin and stop lug, allowing for precise setting and quick return to pre-defined angles, enabling operators to easily adjust and maintain consistent lead or lag angles during welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex apparatuses such as dials and linkages are used to adjust the welding torch angle, then the ability to adjust and re-set at a desired angle is improved, but the device complexity increases and adjustment time is lost
Solution Approach 1:
The adjustment mechanism is segmented into discrete angular positions marked on the torch body, allowing the operator to select from predetermined angles without complex continuous adjustment apparatus. The torch angle adjustment is divided into specific incremental positions rather than requiring continuous rotational control.
Solution Approach 2:
The desired angular positions are pre-marked on the torch body during manufacturing, eliminating the need for complex measurement and calculation during operation. The operator simply aligns the torch with the pre-established angular markings to achieve the desired angle quickly and accurately.
2Adaptability or versatility
If flexible necks, probes or rollers are used to automatically adjust the weld head, then adaptability is improved, but the ability to accurately measure and establish a repeatable reference point deteriorates
Solution Approach 1:
The torch assembly includes self-aligning features where the torch body automatically references the pre-marked angular positions through its own structure, eliminating the need for external flexible necks or probes. The torch serves its own alignment function through integrated angular markings and reference features.
Solution Approach 2:
Complex mechanical adjustment systems such as flexible necks and rollers are replaced with a simplified mechanical reference system using pre-marked angular positions on the torch body. This substitution maintains adaptability while dramatically improving measurement precision and repeatability.
3Measurement precision
If protractors are used to precisely set the lead and lag angle, then measurement precision is improved, but the time required for adjustment increases and operation becomes more difficult
Solution Approach 1:
All angular measurement markings are pre-established on the torch body during manufacturing, eliminating the need for operators to use protractors to measure and calculate angles during production. The desired angular positions are already marked, allowing immediate alignment without measurement time.
Solution Approach 2:
The protractor and external measurement tools are extracted from the adjustment process entirely. The angular measurement function is integrated directly into the torch body through pre-marked positions, removing the separate measurement step and its associated time loss.
Data Source
AI summary
The invention described herein generally pertains to systems and methods related to repeatable and accurate setting of welding torch lead and lag positions, particularly with orbital welding systems. Specifically, a torch is coupled with a lead-lag coupler having a stop lug. A stop set with a stop pin is rotated to a desired position of lead or lag and secured. The lead-lag coupler, and torch which rotates therewith, are then unsecured and rotated until the stop lug contacts the stop pin. In this position, the torch is maintained at the desired angle. The stop pin remains in place throughout operation(s) to permit quick, accurate return to the desired angle if the torch is temporarily moved out of position.