Welding Torch Conical Nozzle for Fume Extraction
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Solution Overview
Problem
Existing welding torch systems do not effectively extract fumes during welding operations, which can be hazardous and require protective gear for welders, necessitating further improvement in fume extraction efficiency.
Innovation Solution
The welding torch system enhances fume extraction by increasing the outlet velocity of shield gas through a conically tapered inner shield gas conduit with a decreasing diameter, promoting a laminar flow and undisturbed gas flow, and optimizing the design of the contact tip holder and outer shell to facilitate efficient fume extraction without interfering with the weld process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the outlet velocity of shield gas is increased to improve fume extraction efficiency, then fume removal effectiveness improves, but the complexity of the shield gas supply system increases
Solution Approach 1:
The patent changes the geometric parameters of the inner shield gas conduit by introducing a conical section with a specific taper angle (α) between 5° and 15°. This parameter change accelerates the shield gas flow from the wider section to the narrower outlet section, increasing outlet velocity and improving fume extraction efficiency without requiring additional complex components or system modifications
Solution Approach 2:
The patent employs a conical (curved/tapered) geometry for the inner shield gas conduit instead of a straight cylindrical shape. This curved/tapered design naturally accelerates the gas flow through geometric convergence, achieving higher outlet velocity and improved fume extraction while maintaining system simplicity
2Productivity
If a conical tapered inner shield gas conduit is used to increase shield gas outlet velocity, then fume extraction improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a relatively wide range for the taper angle (α between 5° and 15°), which provides manufacturing flexibility. This parameter range is wide enough to achieve the desired flow acceleration effect while being tolerant of normal manufacturing variations, thereby reducing precision requirements compared to specifying a very narrow angle range
Solution Approach 2:
The conical taper is applied only to a specific section (the end portion) of the inner shield gas conduit rather than the entire conduit. This localized application of the tapered geometry concentrates the flow acceleration effect where needed while leaving the rest of the conduit with simpler cylindrical geometry, reducing overall manufacturing complexity and precision requirements
3Productivity
If the inner shield gas conduit is narrowed towards the outlet to increase gas velocity, then fume extraction improves, but shield gas flow stability may be compromised
Solution Approach 1:
The gradual conical taper provides a smooth, continuous transition in the conduit cross-section rather than abrupt changes. This smooth curved geometry prevents flow separation and turbulence by gradually accelerating the gas, thereby maintaining flow stability while achieving increased outlet velocity for improved fume extraction
Solution Approach 2:
The conical taper is designed to preemptively establish laminar flow conditions before the gas reaches the outlet. By gradually accelerating the flow through the tapered section, the design prevents the formation of turbulent eddies and flow instabilities that would occur with abrupt narrowing, thus maintaining flow stability while achieving the desired velocity increase
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
This design achieves significant fume extraction, potentially eliminating the need for protective gear by maintaining a correct weld quality and ensuring efficient fume removal within a specific flow range, minimizing interference with the shield gas flow.
Implementation Method 1
the inner shield gas conduit has an end portion having an inner surface of which the diameter decreases towards the shield gas outlet
Implementation Method 2
the inner surface of the end portion is configured for - during operation - generating a substantially undisturbed flow of shield gas or preferably a substantially laminar flow
Implementation Method 3
a fume extracting assembly operatively connectable to the fume extracting passageway for - during operation - extracting fume and ambient air
Data Source
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AI summary
Welding torch system for use in welding or cutting operations during which fume is created. The welding torch system has a welding torch (1) comprising a contact tip holder (2) and a coaxial nozzle (11) comprising an inner shield gas conduit (5) having a shield gas outlet (6) for supplying a shield gas. The inner shield gas conduit (5) surrounds the contact tip holder (2). An outer shell (7) at least partly surrounds said inner shield gas conduit (5). The welding torch system further comprises a shield gas generator and supply unit (12) and a fume extracting assembly (13). The welding torch system is arranged for supplying shield gas through the shield gas outlet at a velocity between about 1.5 m/s and 10 m/s. By operating the fume extracting assembly to generate a flow of between 10 and 100 m 3 /h, preferably a flow of about 55 m 3 /h a reduction in the area of 90%-95% of hazardous fumes can then be realized. A welding torch (1) for use in such a system has an inner shield gas conduit (5) having an end portion with an inner surface of which the diameter decreases towards the shield gas outlet (6). In a method for welding the shield gas is supplied through the shield gas outlet at a velocity between about 1.5 m/s and 10 m/s.