Wire Feed Control Assembly Torque-Locking Collar
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Solution Overview
Problem
Welding torches face challenges with consumable weld wire threading, feed control inadvertent adjustments, and thermal management, leading to inefficiencies and operator discomfort during extended use.
Innovation Solution
A welding torch with a wire feed assembly featuring a motor-driven roll pair, a collar to secure the feed control against accidental adjustments, and a barrel assembly with multiple gas passages for improved thermal separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the feed control is made accessible on the torch for operator adjustment, then ease of operation is improved, but the control becomes susceptible to inadvertent adjustment from impacts and movements
Solution Approach 1:
The feed control mechanism transitions from a static, always-accessible state to a dynamic state where accessibility is controlled. The torquable collar allows the control to switch between locked and unlocked states, enabling operator adjustment when needed while preventing inadvertent changes during normal operation.
Solution Approach 2:
The resistance to rotation of the collar is changed by applying torque, transforming the control from a freely rotatable state to a locked state. This parameter change in rotational resistance allows the system to maintain stability during impacts while remaining adjustable when deliberately operated.
2Ease of operation
If the rolls are kept separated for threading consumable weld wire, then ease of operation is improved, but productivity decreases due to repeated opening and closing during threading process
Solution Approach 1:
The collar is pre-positioned in a locked state that maintains roll separation, allowing threading to begin without requiring repeated manual intervention. The preliminary locking action enables continuous threading operation once initiated, eliminating the need to repeatedly open and close rolls during the process.
Solution Approach 2:
The collar mechanism automatically maintains roll separation through its locked state, providing self-service during the threading process. Once the rolls are initially separated and threading begins, the system maintains itself in the separated state without requiring continuous operator intervention to keep rolls open.
3Productivity
If the torch is designed for extended welding operations, then productivity is improved, but operator fatigue increases due to thermal exposure
Solution Approach 1:
The torquable collar acts as an intermediary mechanism between the operator's hand and the feed control. By providing a deliberate activation requirement through torque application, it mediates between the need for accessibility and the need to prevent inadvertent operation during thermal welding processes.
Data Source
Figure 1
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AI summary
A wire feed assembly and torch and welding systems are disclosed. The wire feed assembly includes a motor drivingly connected to at least one roll of a pair of rolls. A controller (140) is connected to the motor and is constructed to control the operation thereof . A knob (56) is rotatably connected to the controller and facilitates an operator's adjustment of the controller. A collar (260) is disposed between knob and the controller and is fixedly connected to the controller and engaged by the knob to resist movement of the knob and thereby adjustment of the controller.