Interchangeable-Nozzle Welding Torch for Electrode Heat Control
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Solution Overview
Problem
Conventional welding torches require multiple nozzles with different tip sizes for various welding targets and areas, leading to increased costs and serviceability issues, and suffer from thermal deformation of the electrode bar, which affects bearing power and can cause accidents due to heat conductivity.
Innovation Solution
A welding torch with a main body featuring a hollow pipe and an inclined surface for adjustable electrode bar support, a socket for directional gas spraying, and a connector for combined gas and power supply, allowing for nozzle replacement and surface contact electrode bar support to prevent thermal deformation and enhance cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple nozzles with different tip sizes are prepared for different welding targets and areas, then welding versatility is improved, but device complexity and cost increase
Solution Approach 1:
The torch main body is designed with a universal structure that can accommodate multiple nozzles with different tip sizes through a standardized mounting interface. This allows a single torch body to perform multiple welding functions by simply changing the nozzle attachment, eliminating the need for multiple complete torch sets and reducing overall device complexity while maintaining welding versatility.
2Device complexity
If the electrode bar support area is reduced to a point contact, then the torch structure is simplified, but thermal deformation increases and bearing power deteriorates
Solution Approach 1:
The support structure for the electrode bar is changed from a point contact (zero-dimensional) to a surface contact (two-dimensional) arrangement. This dimensional expansion of the support area distributes the thermal load across a larger surface, reducing thermal deformation and improving bearing capacity while maintaining structural simplicity through the use of a collet chuck mechanism.
3Loss of energy
If gas is sprayed in a straight line toward the nozzle, then the cooling effect is concentrated, but arc sparks are directly generated inside the nozzle causing overheating and safety hazards
Solution Approach 1:
The gas spray direction is changed from a symmetric straight-line path directly toward the nozzle to an asymmetric trajectory that bypasses the nozzle interior. The gas is sprayed at an angle or from a position that allows it to cool the electrode bar and surrounding areas without directing the spray stream through the nozzle passage, thereby preventing arc generation inside the nozzle and the associated overheating and safety hazards while maintaining effective cooling.
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
Enables versatile application with interchangeable nozzles, reduces additional costs, minimizes electrode bar movement, and provides continuous welding with reduced heat conductivity risks, preventing accidents such as burns or fires.
Implementation Method 1
some of the gas sprayed in all directions from the inside of the nozzle through the socket gets in contact with the nozzle to cool heat during welding
Implementation Method 2
if a high heat is generated, a supported portion of the electrode bar which is in a point contact is thermally deformed to deteriorate bearing power
Implementation Method 3
a first inclined surface formed in the body pipe; the collet chuck is moved when the joint is tightened or released in such a way that the electrode bar is tightened when the collect chuck gets in contact with the first inclined surface
Data Source
AI summary
A welding torch that comprises: a main body that is formed as a hollow pipe body, and that has a first inclined surface formed inside the pipe body; an electrode bar cap that has a collet chuck on the front side of a joint that is assembled on one side of the pipe body in a screw-coupling manner, that moves the collet chuck by tightening or loosening the joint; a head that has a socket that is arranged on a side facing the pipe body and that sprays supplied gas in all directions, and that is formed of a nozzle that is assembled on an external surface of the socket; and a connector that guides a gas supply into the pipe body.