Welding Torch Cooling Bypass for Leak-Free Head Replacement
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Solution Overview
Problem
In water-cooled welding torches, leakage of cooling water during maintenance can cause welding failures due to water adhesion on the welding wire, and existing solutions do not efficiently manage cooling water flow during torch body replacement, leading to inefficiencies and potential damage.
Innovation Solution
A welding torch cooling system with a bypass flow path and pressure control mechanism that automatically switches cooling water circulation to prevent leakage when the torch head and body are separated, ensuring water is stopped at the flow path tips and allowing maintenance without stopping the cooling water circulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a welding torch is used for high-power welding applications (e.g., 2000 Watts or more), then welding power and productivity are improved, but the cooling system requires more flow rate and pressure which may not be available in confined job sites
Solution Approach 1:
The cooling system is divided into multiple serpentine cooling channels within the torch body, allowing the coolant to flow through a longer path and dissipate heat more efficiently. This segmentation of the cooling path enables the system to handle higher welding powers without requiring proportionally higher coolant flow rates, as each segment contributes to progressive heat removal along the torch assembly.
2Temperature
If the cooling channels are made larger to reduce flow velocity and improve cooling efficiency, then cooling efficiency is improved, but the torch body size increases which reduces maneuverability
Solution Approach 1:
The cooling channels are nested within the torch body structure itself, with the serpentine paths routed through the torch housing and internal components. This nesting approach allows the cooling system to be integrated into the existing torch volume without requiring additional external cooling apparatus, thereby maintaining a compact form factor while achieving effective heat dissipation through the extended serpentine path length.
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
Prevents cooling water leakage during torch body replacement, enhancing maintenance efficiency and reducing the risk of welding failures by ensuring continuous cooling water circulation without manual intervention.
Implementation Method 1
a welding torch cooling system for a welding torch. The welding torch cooling system includes a pump, a reservoir, and a cooling system manifold assembly. The pump is in fluid communication with the reservoir and the cooling system manifold assembly. The cooling system manifold assembly includes a body, an inlet, an outlet, a bypass passage, a first cooling channel, and a second cooling channel.
Data Source
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AI summary
An aspect of the present disclosure provides a welding torch that includes a torch head and a torch body removably connected to the torch head. The torch head includes first and second torch-head flow paths for flowing cooling water, first and second inlets/outlets communicating with the first and second torch-head flow paths, respectively, and a movable part movable in an axial direction of the torch head. The torch body includes a torch-body flow path for flowing cooling water, and first and second connection ports communicating with opposite ends of the torch-body flow path, respectively. The first and second inlets/outlets communicate with the first and second connection ports, respectively, when the torch head and the torch body are connected to each other. The first and second inlets/outlets are closed with the movable part when the torch head and the torch body are separated.