Welding Torch Trigger Mechanism for Rotating Power Connectors
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Solution Overview
Problem
Conventional fixed connections in welding torches lead to mechanical wear and failure of electrical connections due to torsional movement, especially when using rotating power connectors, which are common in robotic and semi-automatic welding applications.
Innovation Solution
A trigger mechanism that transmits control signals through a transmission channel independent of mechanical wear, using wireless transceivers, conductive brushes, inductive or capacitive elements, optical emitters, or mechanical switching mechanisms to maintain stable electrical contact between the weld trigger and control circuitry despite rotational movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed cable connections are used in welding torches, then the structure is simple and easy to manufacture, but mechanical wear and failure occur due to torsional movement during torch manipulation
Solution Approach 1:
The patent applies the dynamics principle by introducing a rotating power connector that allows the cable to rotate independently within the torch handle. This dynamic mechanism enables the cable to accommodate torsional movements during torch manipulation without creating stress concentration, thereby preventing mechanical wear and electrical connection failure while maintaining structural simplicity
Solution Approach 2:
The patent segments the connection system into two independent parts: a fixed external cable connection and a rotating internal power connector. This segmentation allows the cable to remain fixed externally while the internal connector handles rotational movements, separating the functions of power transmission and rotational accommodation to eliminate mechanical wear
2Adaptability or versatility
If the torch is manipulated to reach various locations, then flexibility and adaptability are improved, but the cable is subjected to severe mechanical wear including excessive twisting and deformation
Solution Approach 1:
The rotating power connector provides dynamic rotational freedom that allows the torch to be manipulated to various locations without transmitting torsional stress to the cable. The connector rotates independently to accommodate changes in torch orientation, enabling full adaptability while protecting the cable from mechanical wear
Solution Approach 2:
The rotating power connector acts as an intermediary mechanism between the fixed cable and the movable torch. It mediates the rotational movements by absorbing the torsional stress within its own structure, preventing the transmission of harmful mechanical wear to the cable while maintaining torch flexibility
3Device complexity
If conventional fixed connections are used, then the device complexity is low, but stress concentration occurs at cable bends leading to cable failure
Solution Approach 1:
The rotating power connector introduces a dynamic element that allows the connection system to adapt to stress conditions. By enabling independent rotation, the connector prevents stress concentration at cable bends, distributing mechanical loads away from the cable and preserving its strength without significantly increasing overall system complexity
Data Source
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AI summary
A semi-automatic torch trigger for a rotating power connector in use in a welding torch cables is provided. In some examples, a trigger mechanism is configured to transmit control signals through a transmission channel that is not subject to mechanical wear from rotational movement of the rotating power connector, providing reliable communication between a welding torch trigger and a welding power supply without breaking electrical contact or putting unnecessary strain on the welding cable, even as the welding torch rotates relative to the welding torch cable.