Welding Wire Spool Housing with Pressure-Relief Dehumidification

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Solution Overview

Problem

Existing welding wire magazines face challenges in effectively preventing moisture absorption by welding wires, leading to hydrogen porosity issues in weld seams, particularly with reactive metals like aluminum, due to high temperatures increasing wear and oxidation risks, and requiring costly inert gas supplies for drying.

Innovation Solution

A welding wire magazine with a scavenging air supply system using a flow control unit to adjust scavenging air flow, reducing relative humidity through pressure relief, allowing the use of compressed ambient air for dehumidification, eliminating the need for special gases and minimizing equipment costs and oxidation risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If temperature control is used to reduce humidity in the welding wire magazine, then moisture protection is improved, but device complexity and energy consumption increase

Engineering Contradiction:

Improvemoisture protectionVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the parameter of air pressure (from ambient to positive pressure) to control humidity. By maintaining positive pressure inside the magazine, moisture-laden air is prevented from entering, and any moisture that does enter is pushed out through the pressure differential, eliminating the need for temperature control systems

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the moisture from the system by using a desiccant material (such as silica gel) that absorbs moisture from the air inside the magazine. The desiccant is periodically regenerated by heating, separating the moisture removal function from the main storage system and allowing simple ambient temperature operation

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-affected harmful factors

If temperature control is used to reduce humidity in the welding wire magazine, then moisture protection is improved, but energy consumption increases

Engineering Contradiction:

Improvemoisture protectionVSAvoidenergy consumption

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The desiccant material automatically absorbs moisture from the air inside the magazine without requiring external energy input. The system uses the natural pressure differential and the passive adsorption properties of the desiccant to remove moisture, with regeneration occurring periodically without continuous energy consumption

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If hermetic sealing and pressurization with inert gas are used to prevent moisture penetration, then moisture protection is improved, but device complexity and operational difficulty increase

Engineering Contradiction:

Improvemoisture protectionVSAvoidoperational difficulty

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the parameter of air pressure from ambient to positive pressure using a simple diaphragm pump, eliminating the need for hermetic sealing and inert gas pressurization. The positive pressure system allows for simple breathability while still preventing moisture ingress

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a desiccant material as an intermediary substance that absorbs moisture from the air inside the magazine. This desiccant acts as a buffer between the external humid environment and the welding wire, allowing the magazine to be breathable while still protecting the wire from moisture

Inventive Principle:

Principle #24Intermediary (Mediator)

4Object-affected harmful factors

If hermetic sealing is used to prevent moisture penetration, then moisture protection is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvemoisture protectionVSAvoidease of operation

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

5Object-affected harmful factors

If inert gas or dry air is used to flush the welding wire magazine, then moisture protection is improved, but cost increases

Engineering Contradiction:

Improvemoisture protectionVSAvoidcost

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

6Object-affected harmful factors

If continuous flushing with inert gas is used to keep water away from the welding wire, then moisture protection is improved, but loss of substance increases

Engineering Contradiction:

Improvemoisture protectionVSAvoidloss of substance

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

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 solution effectively reduces moisture in the welding wire magazine, minimizing hydrogen entry and oxidation, while using readily available compressed air, reducing operational costs and enhancing safety by eliminating the need for inert gas supplies and complex sealing systems.

Implementation Method 1

a flow control unit (14) arranged in the scavenging air supply line (13), which adjusts the flow of scavenging air through the welding wire magazine (1), a first pressure (p) acts in front of the flow control unit (14) in the scavenging air supply line (13), after the flow control unit (14) in the scavenging air supply line (13) and on the scavenging air supply (15) a second pressure (p1) acts, which is lower than the first pressure (p)

Methodology Applied

Scientific EffectPressure relief: Pressure Drop

Implementation Method 2

the relative humidity of the scavenging air being reduced by the pressure relief from the first pressure to the second pressure

Methodology Applied

Scientific EffectPressure-dependent humidity reduction: Pressure Drop

Data Source

PatentEP3218135B1Welding wire sool housing with humidity protection

Publication Date: 2020.02.19 FRONIUS INT GMBH

Figure 1
Figure 2
Figure 3~4

AI summary

The aim of the invention is to reduce the collection of moisture on a welding wire (2, 2', 2") arranged in a welding wire cartridge (1, 1a, 1b) or to remove moisture present on the welding wire in a simple and reliable manner. This is achieved in that a flow (D1) of purge air supplied to the welding wire cartridge (1, 1a, 1b) is adjusted by a flow regulator (14), the purge air is supplied to the flow regulator (14) with a first pressure (p) and is discharged at a purge air outlet (24) of the welding wire cartridge (1, 1a, 1b) with a third pressure (pat), and a second pressure (p1) which is lower than the first pressure (p) is produced at a purge air inlet (15) of the welding wire cartridge (1, 1a, 1b) from the adjusted flow (D1), the third pressure (pat), and a flow resistance between the purge air inlet (15) and the purge air outlet (24), wherein the relative moisture (r F1) of the purge air is reduced by the relief of pressure from the first pressure (p) to the second pressure (p1).