Lateral-Fed Welding Torch Wire Guide for Tight Clearance
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Solution Overview
Problem
Conventional welding torches require significant clearance above the workpiece due to the axial arrangement of components, limiting their use in constricted spaces and orbital pipe welding applications.
Innovation Solution
The design of a low-profile electric arc torch with a wire guide channel that bends the wire electrode laterally into the contact tip, reducing the need for overhead clearance by feeding the wire electrode and shielding gas through a lateral side, allowing for operation within a tighter space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wire electrode is fed axially through the torch body from above, then the wire electrode can be delivered to the contact tip, but a significant amount of clearance above the workpiece is required to accommodate the torch and cable
Solution Approach 1:
The wire electrode feeding direction is changed from axial (vertical) to lateral (horizontal), entering the torch body through the side rather than from above. This dimensional change allows the wire guide channel to bend the wire at approximately 90 degrees, significantly reducing the overhead clearance requirement while maintaining proper wire delivery to the contact tip
2Ease of operation
If the torch cable curves into the top of the torch body, then the wire electrode can be supplied, but clearance space above the workpiece is required
Solution Approach 1:
The cable entry point is moved from the top of the torch body to the lateral side, changing the torch profile from a top-fed configuration to a side-fed configuration. This allows the cable to approach horizontally rather than curving down from above, reducing the vertical profile and clearance space requirement
3Ease of operation
If the wire guide channel has a reverse curve shape with multiple curved portions, then the wire electrode feeding direction can be turned by at least 90 degrees, but the wire guide structure becomes more complex
Solution Approach 1:
The wire guide channel incorporates curved portions with specific radii of curvature to smoothly redirect the wire electrode by at least 90 degrees from lateral to axial direction. The curved geometry, rather than sharp angles, reduces wire friction and feeding resistance while maintaining a compact torch structure
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 enables welding and additive manufacturing operations within a reduced overhead clearance, enhancing versatility and efficiency in confined spaces while maintaining effective arc generation and material deposition.
Implementation Method 1
The first curved portion is located between the wire receiving end and the second curved portion, and is configured to turn a feeding direction of a wire electrode received at the wire receiving end by at least 90 degrees
Implementation Method 2
The present invention relates to torches for generating electric arcs
Data Source
AI summary
An electric arc torch includes a torch body and a gas diffuser extending from a distal side of the torch body. A contact tip is attached to the gas diffuser. The contact tip has a bore extending along a first axis. A wire guide is located within the torch body and has a wire guide channel that extends from a wire receiving end of the wire guide channel to a wire discharge end of the wire guide channel. The wire discharge end is aligned with the bore of the contact tip. A wire electrode conduit extends from a lateral side of the torch body and is configured to discharge a wire electrode into the wire receiving end of the wire guide channel and along a second axis. An angle between the first axis and the second axis is not greater than 90 degrees.