Welding Wire Preheating in Liquid-Cooled Torch Assemblies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current welding techniques lack a method to ensure the electrode wire is heated prior to initiating a welding operation, affecting the consistency and efficiency of the welding process.
Innovation Solution
A liquid-cooled welding torch system that incorporates a preheating mechanism to heat the electrode wire using resistive heating, allowing for consistent and efficient welding by superimposing preheating current with the welding current through the electrode wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding techniques are used without preheating, then the welding system is simple and easy to operate, but the welding performance is inconsistent and efficiency is reduced
Solution Approach 1:
The patent combines the preheating function and welding function into a single integrated torch system. The preheating circuit and welding circuit share common components including the contact tips, electrode wire path, and liquid cooling system. This merging allows the system to provide both preheating and welding operations without requiring separate equipment, thus improving welding performance consistency while avoiding excessive system complexity.
Solution Approach 2:
The torch assembly is designed to perform multiple functions: it can conduct preheating current through the electrode wire, conduct welding current through the same path, and provide liquid cooling for both operations. The contact tips and wire guide serve universal purposes for both preheating and welding, making the system multi-functional and reducing the need for separate dedicated equipment.
2Productivity
If preheating current is superimposed with welding current, then deposition rate improves, but energy consumption increases
Solution Approach 1:
The system applies preheating current continuously to the electrode wire before and during the welding operation. By maintaining continuous heating of the wire as it feeds through the contact tips, the system ensures the wire is always at an optimal temperature for deposition, thereby improving deposition rate. The continuous action eliminates interruptions and maintains productive heat levels throughout the welding process.
Solution Approach 2:
The system changes the temperature parameter of the electrode wire by superimposing preheating current with the welding current. This parameter change (increasing wire temperature) directly improves deposition rate by reducing thermal gradients and improving metal flow. The controlled change in temperature parameter allows optimization of the welding process efficiency.
3Productivity
If the torch design is modified to include preheating capability, then welding efficiency improves, but the risk of collisions increases
Solution Approach 1:
The torch maintains a conventional external appearance and dimensions while incorporating preheating capability internally. The contact tips, wire guide, and cooling system are integrated into the existing torch structure without increasing its overall envelope. This allows the modified torch to fit within existing robotic workspaces and avoid collisions with workpiece features or fixtures that would occur with a larger dedicated preheating device.
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
The system ensures consistent electrode heating, improving welding starts and deposition rates while maintaining the same tool center point distance and torch neck angle as conventional systems, reducing the need for reprogramming and minimizing the risk of collisions.
Implementation Method 1
A liquid-cooled welding torch system that incorporates a preheating mechanism to heat the electrode wire using resistive heating
Implementation Method 2
A liquid-cooled welding torch system that incorporates a preheating mechanism
Implementation Method 3
Electrical power is applied to the welding wire and a circuit is completed through the workpiece to sustain a welding arc that melts the electrode wire and the workpiece to form the desired weld
Data Source
AI summary
Systems, methods, and apparatus to preheat weld wire are disclosed. An example contact tip includes: an inner bore configured to conduct current to a consumable welding electrode; screw threads on an exterior of the contact tip; and a head opposite the screw threads on an exterior of the contact tip to enable threading and dethreading of the contact tip.