Welding Torch Power Feed Tip Heat Management

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Solution Overview

Problem

Conventional consumable electrode gas shield arc welding torches face challenges in maintaining the accuracy of the welding wire position due to non-uniform bending, leading to inconsistent welds and frequent wear and replacement of the power feed tip due to arc heat, which reduces operational efficiency and extends the lifetime of the power feed tip.

Innovation Solution

The design incorporates a power feed tip with a tapered portion and vertical slits, pressed by a spring and tip holder, creating a space that reduces direct heat transfer and maintains the power feed tip's hardness, along with a heat-resistant tip holder to prevent overheating and extend the tip's lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If the welding wire is fed through a conventional power feed tip without space between the tip holder and tip, then the structure is simple and compact, but the power feed tip overheats due to direct heat transfer from the arc, causing wear and short lifespan

Engineering Contradiction:

Improvepower feed tip lifespanVSAvoidpower feed tip temperature

Core Design Contradiction:

Duration of action of stationary objectVSTemperature

Solution Approach 1:

The patent introduces a tip holder as an intermediary component between the arc and the power feed tip. The tip holder creates a physical barrier and thermal isolation layer, preventing direct heat transfer to the power feed tip. This mediator absorbs and dissipates heat away from the power feed tip, reducing its operating temperature and extending its lifespan without compromising the electrical connection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the power feed tip is pressed tightly against the tip holder to ensure good electrical contact, then the electrical conductivity is improved, but the heat transfer to the power feed tip increases, causing overheating and wear

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidheat transfer to power feed tip

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating a differentiated contact structure: the power feed tip maintains intimate contact with the tip holder at the electrical contact surface to ensure low-resistance electrical connection, while the outer surface of the tip holder that contacts the tip body is designed with thermal isolation properties. This localized differentiation allows simultaneous optimization of electrical conductivity and thermal management in different regions of the same component interface.

Inventive Principle:

Principle #3Local quality

3Ease of operation

If the welding wire bending is not uniform, then the wire can be easily fed through the system, but the contact point between the welding wire and power feed tip varies, causing inconsistent arc length and non-uniform welds

Engineering Contradiction:

Improvewiring easeVSAvoidweld bead uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent implements a self-adjusting mechanism where the power feed tip is designed with flexibility and compliance features that allow it to automatically adapt to variations in welding wire position caused by bending. The tip can self-adjust its contact point along the wire length, maintaining consistent electrical contact and arc length despite wire position variations, thereby eliminating the need for precise wire feeding control while maintaining weld quality.

Inventive Principle:

Principle #25Self-service

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 configuration enhances the stability and accuracy of the welding process by preventing overheating and wear of the power feed tip, extending its lifespan and ensuring consistent weld quality while reducing the need for frequent replacements.

Implementation Method 1

a spring (26) provided in the tip body (22) to come into contact with the front end (21a) of the torch body (21)

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a space (29) is defined between an inner surface of the tip holder (23) and a front end (28a) of the power feed tip (28)

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 3

electric power is supplied from a welding power source (7) to the welding torch (3)

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 4

the arc, the molten pool and the nearby portion from nitrogen and oxygen in the air

Methodology Applied

Scientific EffectElectric Arc: Electric Arc

Data Source

PatentUS9889518B2Consumable electrode gas shield arc welding torch and power feed tip

Publication Date: 2018.02.13 DAIHEN CORP

AI summary

A consumable electrode gas shield arc welding torch (20) includes a torch body (21), a tip body (22) mounted to a front end of the torch body, a tip holder (23) mounted to a front end of the tip body, a spring (26) provided in the tip body (22) in contact with the front end of the torch body (21), a pressing shaft (27) provided in the tip body (22) in contact with a front end of the spring 26) and a power feed tip (28) pressed by the pressing shaft (27) and the tip holder (23). The tip (28) includes a side surface having a projection contacting with a base end (23a) of the holder (23), with a space (29) defined between an inner surface of the holder (23) and a front end (28a) of the tip (28) when the front end (28a) of the tip (28) is inserted into the holder (23).