Welding Wire Feed Path Reorientation for Multi-Wire Torch Compactness
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Solution Overview
Problem
In the automotive industry, existing welding machinery is expensive, requires high maintenance, and occupies significant space, making it inefficient for providing different welds.
Innovation Solution
A welding device with a feed device that transfers welding wire from one orientation to another, utilizing a conical or curved feed surface and an elongate line element to accommodate multiple wire cores, along with an alignment and separating device for precise gas and power supply, ensuring only one wire is used for the weld seam, and a method for operating a multi-axis robotic arm to manage separate welding wire paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate welding torches are used to provide different welds, then welding versatility is improved, but device complexity and space occupation increase
Solution Approach 1:
The patent implements a single welding torch that can handle multiple welding wire types (e.g., aluminum, stainless steel, carbon steel) through a universal wire guide device with adjustable geometry. The guide device can be configured for different wire diameters and materials, allowing one torch to perform functions previously requiring multiple specialized torches, thereby reducing device complexity while maintaining welding versatility
Solution Approach 2:
The wire guide device is segmented into adjustable components that can be independently configured for different wire types. The guide device includes adjustable guide surfaces and positioning elements that can be modified to accommodate various wire geometries, enabling a single torch to handle multiple welding processes without requiring complete torch replacement
2Adaptability or versatility
If multiple separate welding torches are used to provide different welds, then welding versatility is improved, but space occupation increases
Solution Approach 1:
The patent implements a single welding torch that can handle multiple welding wire types (e.g., aluminum, stainless steel, carbon steel) through a universal wire guide device with adjustable geometry. The guide device can be configured for different wire diameters and materials, allowing one torch to perform functions previously requiring multiple specialized torches, thereby reducing device complexity while maintaining welding versatility
Solution Approach 2:
The patent merges multiple wire feeding paths into a single common path within the wire guide device. Different wire sources can be fed through separate initial paths that converge into a shared guide structure, allowing multiple wire types to be managed through one torch assembly, thus reducing the space required compared to having separate torches for each wire type
3Ease of operation
If welding wire is conveyed through a hose package with friction losses, then wire feeding is simplified, but conveying force is lost
Solution Approach 1:
The patent extracts the welding wire from the flexible hose package and guides it through a rigid, dedicated wire guide device with optimized geometry. This separate wire guide structure minimizes friction and bending losses by providing a smooth, purpose-designed path, thereby preserving conveying force while maintaining ease of wire feeding operation
Solution Approach 2:
The wire guide device incorporates optimized curved surfaces and rounded transition zones that reduce sharp bends and minimize friction losses. The guide geometry is designed with appropriate radii to smoothly guide the wire through the torch assembly, reducing mechanical resistance and preserving conveying force during wire feeding
Data Source
Figure 1a~1c
Figure 2
Figure 3a~3f
AI summary
The invention relates to a welding device (1) comprising: • a current contact nozzle (2), wherein the current contact nozzle (2) has an elongate guide device for guiding a welding wire (4), • a contact tip holder (6), wherein the current contact nozzle (2) is arranged on or in the contact tip holder (6), • a feed device (100) for transferring the welding wire (4) from a first orientation into a second orientation, wherein in the first orientation the welding wire (4) can be fed to the feed device (100), and in the second orientation it can be led out of the feed device (100), in particular in the direction of the contact tip holder (6), wherein the feed device (100) has a preferably conical feed face (102), • an elongate conduit element (200), wherein a plurality of welding wire cores (8, 10) can be accommodated by the conduit element (200), wherein the welding wire cores (8, 10) can be introduced into the conduit element (200) via a first conduit element end (202), and wherein the welding wire (4) which is guided in the welding wire cores (8, 10) can be guided out of the conduit element (200) via a conduit element end (204), and wherein the welding wire (4) which is guided out of the conduit element (200) via the second conduit element end (204) can be led in the direction of the feed device (100), in particular enters the feed device (100) in the first orientation.