Concentric Welding Torch Nozzle Layout for Stable Arc Shielding
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Solution Overview
Problem
Existing welding torches face challenges when welding low-melting metals, such as galvanized steel sheets, due to the formation of zinc vapor and fumes that can lead to unstable arcs and defective welds. Additionally, complex structures and offset nozzle axes can result in uneven plasma gas flow, affecting welding quality.
Innovation Solution
A simplified welding torch design featuring a non-consumable electrode, concentrically disposed inner and outer nozzles, and an electrode extrusion member. This configuration allows for independent adjustment of inert gas flow rates and maintains a concentric alignment of components, even if the electrode is slightly bent, ensuring consistent plasma gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the tip of the electrode protrudes from the tip of the nozzle in TIG welding, then the electrode is exposed and ready for welding, but metals in fumes attach to the electrode tip causing unstable arc and ignition failure
Solution Approach 1:
The patent introduces a shield gas flow path that provides shield gas between the electrode tip and the external environment. This shield gas acts as an intermediary protective layer that prevents metal fumes from attaching to the electrode tip while maintaining electrode exposure for welding operations, thereby resolving the contradiction between ease of operation and arc stability
Solution Approach 2:
The patent creates an inert atmosphere by supplying shield gas (such as argon or helium) around the electrode tip. This inert gas environment prevents oxidation and contamination of the electrode tip by metal fumes, ensuring stable arc ignition and maintenance during welding while keeping the electrode tip exposed and ready for operation
2Object-affected harmful factors
If the insert tip structure is added with multiple plasma gas discharge holes to reduce fume attachment, then fume attachment is reduced, but the structure becomes complex and the tip size increases
Solution Approach 1:
The patent extracts the fume protection function from the insert tip structure itself and relocates it to a separate shield gas supply system. Instead of modifying the insert tip with multiple holes, the shield gas is supplied through dedicated flow paths that surround the electrode, thereby reducing fume attachment while maintaining simple insert tip structure
Solution Approach 2:
The patent segments the gas protection functions into separate systems: shield gas supply for electrode protection and plasma gas supply for arc confinement. This segmentation allows the insert tip to remain simple while the shield gas system handles fume protection, avoiding the need for complex multi-hole insert tip structures
3Adaptability or versatility
If the axis of the insert tip is offset from the axis center of the electrode, then the insert tip can be positioned around the electrode, but the plasma gas flow becomes uneven and welding quality deteriorates
Solution Approach 1:
The patent introduces shield gas as an intermediary that compensates for misalignment between the insert tip axis and electrode axis. The shield gas flows uniformly around the electrode from multiple directions, creating a balanced protective atmosphere that compensates for the offset positioning, thereby maintaining both adaptability in positioning and uniformity in welding quality
Solution Approach 2:
The patent utilizes the fluid phase properties of shield gas to achieve uniform distribution around the electrode. The gas phase allows the shield gas to flow and distribute evenly around the electrode regardless of insert tip offset, creating a uniform protective atmosphere that maintains welding quality while allowing flexible positioning
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 enhances welding quality by preventing fume attachment to the electrode and nozzle tips, maintaining arc stability, and improving the concentration of the plasma arc, even when welding low-melting metals.
Implementation Method 1
a first gas flow path for flowing a first inert gas is provided between the non-consumable electrode and the inner nozzle
Implementation Method 2
a second gas flow path for flowing a second inert gas between the inner nozzle and the outer nozzle
Implementation Method 3
the inner nozzle is concentrically disposed outwardly of the electrode extrusion member... maintaining a concentric alignment of components, even if the electrode is slightly bent, ensuring consistent plasma gas flow
Implementation Method 4
an arc is usually generated between an electrode (a non-consumable electrode) composed of tungsten and a welded material, and the heat of the arc melts the welded material
Data Source
AI summary
A welding torch includes a non-consumable electrode extending along an axial direction, a first member disposed outwardly of the non-consumable electrode, an inner nozzle disposed outwardly of the non-consumable electrode, an engaging member disposed outwardly of engaging with the first member and the inner nozzle, an outer nozzle disposed outwardly of the inner nozzle, and an electrode extrusion member disposed outwardly of the non-consumable electrode and inwardly of the inner nozzle. The electrode extrusion member is concentrically disposed outwardly of the non-consumable electrode, and the inner nozzle is concentrically disposed outwardly of the electrode extrusion member. A first gas flow path for flowing a first inert gas is provided between the non-consumable electrode and the inner nozzle. A second gas flow path for flowing a second inert gas is provided between the inner nozzle and the outer nozzle.