Welding Torch Motor Cooling Layout for Easy Replacement
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Solution Overview
Problem
Conventional welding torches with integrated wire feeding motors face challenges in motor replacement and cooling efficiency, where the motor housing also serves as the base body, making replacement difficult and cooling inefficient, either from outside or inside the torch housing.
Innovation Solution
The welding torch design incorporates two coolers that sandwich the motor from both sides, allowing for easy motor replacement and enhanced cooling, with adjustable cooler shapes to accommodate varying motor sizes and thermal conductivity, and a connecting mechanism to protect against spatters and improve handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the motor housing serves as the base body (integrated design), then the fabrication tolerance between motor shaft and welding wire feeding shaft decreases, but the ease of motor replacement deteriorates
Solution Approach 1:
The base body is divided into two separate components: a motor housing that accommodates the motor, and a torch housing that contains the wire feeding mechanism. These housings are connected via a motor holder, allowing the motor to be replaced independently while maintaining precise alignment through the motor holder's positioning features.
2Ease of operation
If the motor is cooled from outside the torch housing, then the ease of operation improves, but the cooling efficiency deteriorates
Solution Approach 1:
A motor holder is introduced as an intermediary component between the motor housing and torch housing. The motor holder includes a motor cooling portion with cooling fluid supply and discharge ports that connect to the torch housing, enabling efficient cooling while maintaining ease of operation.
3Loss of energy
If the motor is cooled inside the torch housing, then the cooling efficiency improves, but the volume of the torch housing increases
Solution Approach 1:
The cooling fluid passages are arranged in a compact configuration within the motor holder and torch housing interface, utilizing vertical and lateral space efficiently. The cooling ports are positioned to minimize the horizontal footprint while maintaining effective thermal contact with the motor.
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
Facilitates motor replacement and improves cooling performance, ensuring efficient heat dissipation even during high-speed welding, while maintaining a compact design and protecting the motor from external damage.
Implementation Method 1
the first cooler and the second cooler cover the motor so as to sandwich the motor from both the side surfaces
Implementation Method 2
the first cooler and the first side surface or the second cooler and the second side surface may be connected via a thermally conductive member
Data Source
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AI summary
To provide a compact welding torch in which a motor can be easily replaced, in which, when a motor capable of high-speed welding is used for a long time in a high current region, heat generated by the motor can be sufficiently cooled, and in which the motor can be protected from spatters or the like. A first cooler that cools a first side surface of a motor parallel to a shaft of the motor and a second cooler that cools a second side surface of the motor different from the first side surface are included. The first cooler has a first inflow port and a first outflow port for a cooling fluid, and a first flow passage that connects the first inflow port and the first outflow port. The second cooler has a second inflow port and a second outflow port for the cooling fluid, and a second flow passage that connects the second inflow port and the second outflow port. The first outflow port and the second inflow port open in a direction crossing the shaft of the motor and are connected to each other directly or indirectly.