Patent Application
20250001515
This disclosure relates generally to fume extraction, and more particularly to fume extractors for welding torches.
Welding operations result in substantial fumes which, if not captured, disperse into the local environment (e.g., room, building) in which the welding operations are occurring. Such fumes or other airborne components may dissipate, or be captured and filtered from the air.
Different types of fume extraction systems have been developed. Some types of fume extractors filter fume from ambient air, which generally requires the fumes to have dispersed into the local environment in which the filter is located. Some other types of fume extractors include localized collection devices, which can be positioned to collect air and fume from a more localized volume within which the fumes originate, thereby increasing capture efficiency. In the welding context, such localized fume extractors can be coupled or attached to a welding torch to generally follow a fume-producing arc welding operation, or can be positioned independently from the welding torch.
Fume extractors for metal inert gas (MIG) welding torches are disclosed, substantially as illustrated by and described in connection with at least one of the figures, as set forth more completely in the claims.
The figures are not necessarily to scale. Where appropriate, similar or identical reference numbers are used to refer to similar or identical components.
Disclosed example fume extractors provide improved fume at the point of fume generation extraction for welding torches. In disclosed examples, a fume extractor attachment is mounted onto the welding torch (e.g., a metal inert gas (MIG)), in which the fume extractor attachment enables fume extraction at a location adjacent to a nozzle of the welding torch, which captures and channels fumes for collection and filtering. Disclosed example fume extractor attachments enable an operator to modify a variety of torches to easily add fume source capture capabilities to a standard welding torch, thereby providing improved fume extraction efficiency by locating the fume extraction closer to the welding arc.
Fume capture in welding environments can be performed in a number of ways. Ambient systems are used to draw in fumes in an area around the weld site, often via tubing or manifolds that draw air into a vacuum source. Source capture systems can be implemented as a fume gun. A fume gun can be implemented as a MIG welding torch, with the addition of a source capture fume nozzle integrated into a portion of the welding torch. In such a torch, the fume nozzle is located just above the nozzle near the contact tip, which draws in fumes from the welding operation as soon as it is generated.
Such welding torches and fume source capture systems are effective and work as intended. However, such systems are typically fully integrated with a give torch, only compatible with large frame welding machines, and are expensive. Thus, if an operator sought source capture capabilities, the operator would need to buy an entire fume gun system compatible with specific machines.
The design of the disclosed fume extraction attachment addresses these challenges, providing an attachment that can be mounted to a variety of welding torches (e.g., a MIG welding torch), converting a standard welding torch into a fume capture torch. As explained herein, the fume extraction attachment can be made available at a fraction of the cost of previous fume extraction torches, and operators can use existing welding torches, power supplies, and vacuum systems.
Advantageously, the disclosed attachment can be mounted to a wide variety of welding torches, including type and/or brand of torch, and can be removed and re-mounted as needed. The design can be a consumable product, manufactured at a cost to allow for replacement as-needed. The fume extractor system can be connected to a wide variety of vacuum systems as well.
In disclosed examples, a fume extractor attachment for a welding torch, the fume extractor attachment including a body including a neck channel to receive a neck of a metal inert gas welding torch; a plurality of fume slots arranged at a first end of the body; a fume duct receiver arranged at a second end of the body opposite the first end; and a fume manifold providing fluid communication between the one or more fume slots and the fume duct receiver, the fume duct receiver being couplable to a fume hose.
In some examples, the channel is straight. In examples, the channel has one or more curves.
In some examples, the plurality of fume slots are formed in a conical portion extending from the body toward a nozzle of the welding torch. In examples, the plurality of fume slots are arranged radially about the channel. In examples, the channel extends from the conical portion to an opening configured to receive the neck of the welding torch. In examples, the manifold extends into a space within the body and the conical portion that surrounds the channel.
In some examples, the channel is fluidly sealed from the fume manifold. In examples, the fume manifold comprises a material with a melting point above a predetermined threshold temperature. In examples, the material comprises one or more of a metal, a polymer, polyetheretherketone (PEEK), polyimide, or silicone.
In examples, the attachment is formed as a single unit.
In examples, the body comprises two or more pieces configured to be attached together to clamp onto the neck of the welding torch.
In examples, the fume extractor attachment includes one or more fasteners to fix a position or orientation of the fume extractor attachment relative to the welding torch.
In examples, the fume extractor attachment includes an insulator between one or more surfaces of the fume extractor attachment and the neck of the welding torch.
In some disclosed examples, a fume extractor system for a welding torch includes a vacuum system; a fume hose connected to the vacuum system; and a fume extractor attachment comprising: a body including a neck channel to receive a neck of a metal inert gas welding torch; a plurality of fume slots arranged at a first end of the body; a fume duct receiver arranged at a second end of the body opposite the first end; and a fume manifold providing fluid communication between the one or more fume slots and the fume duct receiver, the fume duct receiver being couplable to the fume hose.
In some examples, the welding torch is connected to a robotic welding arm.
In examples, the robotic welding torch is connected to one or more weld cables to deliver welding consumables from a welding power supply.
In examples, the fume extractor system includes a hose support to hold the fume hose.
In examples, the hose support is configured to move in at least one direction in response to movement of the fume hose.
In some examples, the fume extractor system includes a grommet arranged between the fume extractor attachment and the neck of the welding torch to partially seal a space between the fume extractor attachment and the neck
Welding operations generate substantial fumes which, if not captured, disperse into the local environment (e.g., room, building) in which the welding operations occur. To effectively capture and dispose of welding fumes generated by the welding torch, a fume extraction system 103 is attached to the welding torch 104 to capture welding fumes close to the point of emission of the fumes. Because the fume extraction system 103 is attached to the welding torch 104, the fume extraction system 103 moves with the welding torch 104 as the manipulator 106 conducts the welding operations.
In the example shown in
Additionally or alternatively, disclosed fume extractor attachments may be adapted for multiple different types of robotic welding torches and/or robotic manipulators, which may include welding torches having liquid cooling lines extending along the neck. Disclosed example fume extractor attachments are easily installed and removed from the welding torch, reducing downtime of the robotic welding system to install, remove, and/or replace components of the fume extractor system.
To reduce or prevent damage to the nozzle assembly, neck, welding torch, and/or robot caused by such a collision, the cushion sections 1206 of the bumper 1104 deflect to absorb contact with the nozzle. For example, one, two, or more of the cushion sections 1206 resiliently deform in response to an external force applied to the rigid frame ring.
Although the first end 122 is illustrated as having a generally conical shape, other shapes and/or designs are considered. Further, although the slots 124 are illustrated as having a generally oval shape, other shapes and/or designs (e.g., circles, triangles, rectangles, holes, etc.) are considered.
One or more fasteners 123 can be included on the fume extraction attachment 102 to fix a position or orientation of the attachment 102 relative to the torch 104A. Such fasteners 123 can include screws, clamps, retaining rings, bolts, clips, friction supports, or elastic bands, as a list of non-limiting examples. Such fasteners 123 can be located within the body 126 (e.g., a friction support at an interface between the neck 110A and an inside surface of the body 126), through a wall of the attachment 102 (e.g., a screw), and/or arranged about the body 126 to fix the position/orientation of the attachment 102 relative to the neck 110A.
In some examples, the fasteners 123 includes one or more internal features at the interface between the attachment 102 and the welding torch. Such internal features may include vanes or baffles, which may retain the attachment 102 in a concentric position relative to the neck 110 of the welding torch 104.
In some examples, as shown in
In the example of
The illustrated dimensions of the disclosed attachments can be modified for a specific torch type, application, and/or fixturing technique. For example, if fasteners are not used, a smaller channel may be used to more securely position the attachment on the neck. A larger channel can be used for larger neck diameters, but also for mounting to a variety of neck diameters. The inlet and/or channel angle relative to the fume duct receiver 120 may be modified for a specific torch and/or application (e.g., 30, 45, 60, 90 degrees, etc.).
The disclosed attachments can be formed of a heat resistant material suitable for welding conditions, such as one or more of a metal, a polymer, polyetheretherketone (PEEK), polyimide, or silicone, as a list of non-limiting examples. In some examples, the material is selected to reduce an amount of spatter that collects on the attachment during a welding operation, and/or is able to be cleaned after the welding operation. In some examples, the attachment includes an insulator, which may be incorporated as a layer (e.g., on one or more surfaces of the attachment), and/or separately formed and mated to the attachment. The insulator may be removable, such that the insulator (or other layer) may be placed on an exposed surface of the attachment, thereby ensuring the attachment is protected (e.g., from heat and splatter), and can be removed following the welding operation. The insulation material can include one or more of glass, silicon, PEEK, or metal, as a list of non-limiting examples. Them attachment can be made as a rigid or a flexible device, can be formed as a single unit (e.g., by injection molding and/or 3D printing techniques), or as multiple pieces that can be assembled to mount to the welding torch. The pieces may be connected by one or more screws or other fasteners, by a hinge and clamp, multiple clamps, retaining rings, clips, and/or any other method of connecting the pieces.
Additionally or alternatively, fume hose 136 can be supported by a hose support system that includes a hose support frame 142, a hose support cable 144, and a hose clamp 145. In some examples, the support frame 142 can be movable to follow movement of the welding torch 104. The support cable 144 can be a material or structure (e.g., elastic, a pulley, etc.) to maintain the hose at a level above the work piece or work surface 114). The example hose support system lessens the likelihood of collisions between the fume extraction system 102 and external objects, such as a workpiece, fixturing, or welding table 114.
As shown, the example fume hose 136 is coupled to the fume duct receiver 120, connected to a cylindrical mounting surface of fume duct receiver 120 using, for example, a hose clamp. In other examples, the outer diameter of the fume duct receiver 120 may be larger than an inner dimeter of the fume hose 136, and the fume hose 136 is stretched over the mounting surface of the fume duct receiver 120 and is retained by compression. Example materials for the fume hose 136 may include a flexible material and may be constructed using a preformed spring wrapped in a fabric or other material that is flexible and resistant to welding-related heat and flame.
In the example of
In some examples, the grommet 150 is wrapped around the neck, with the attachment body being clamped on before or after placement of the grommet. The grommet 150 may be formed of a single piece of material or a combination of two or more materials, including a polymer, silicon, silicone, rubber, polyetheretherketone (PEEK), polyimide, metal, or carbon, as a list of non-limiting examples. As a result, grommet 150 forms a ring about the neck, thereby sucking the air into the attachment 102 via the slots 124, concentrating exhaust and increasing airflow of welding fumes away from the welding site.
In the example of
As shown, the partitions 176 are arranged to create pathways that promotes airflow evenly about the attachment 162. For example, a first, smaller pathway 172 is connected to first, closer slots 164A. The airflow travels a shorter distance from slot 164A through the first pathway 172 to the hose, in comparison to the airflow pathway from second, farther slots 164B. Thus, slots 164B channel airflow through the second, larger pathway 174 and then into the hose. This arrangement promotes a more even suction profile about the attachment 162, and therefore at the welding site.
In some examples, the baffle 170, and/or the coupling 160 in its entirety, is removable. In some examples, the baffle 170 is formed as an integral part of the assembly 162, which may include formation of the first and second pathways to the respective slots. Although two pathways of each type are shown, the baffle may be designed to form a single pathway, or three or more pathways (e.g., four, five, six, seven, eight, nine, ten or more pathways). In some examples, each slot 164A and/or 164B may have a dedicated pathway.
As utilized herein, “and/or” means any one or more of the items in the list joined by “and/or”. As an example, “x and/or y” means any element of the three-element set {(x), (y), (x, y)}. In other words, “x and/or y” means “one or both of x and y”. As another example, “x, y, and/or z” means any element of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means “one or more of x, y and z”. As utilized herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As utilized herein, the terms “e.g.,” and “for example” set off lists of one or more non-limiting examples, instances, or illustrations. As utilized herein, circuitry is “operable” to perform a function whenever the circuitry comprises the necessary hardware and code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or not enabled (e.g., by a user-configurable setting, factory trim, etc.).
While the present method and/or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, systems, blocks, and/or other components of disclosed examples may be combined, divided, re-arranged, and/or otherwise modified. Therefore, the present method and/or system are not limited to the particular implementations disclosed. Instead, the present method and/or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.
This application is a Non-Provisional Patent application claiming priority to U.S. Provisional Patent Application No. 63/510,784 entitled “Fume Extractor Attachments For Welding Torches” filed Jun. 28, 2023, which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63510784 | Jun 2023 | US |
