Patent Application
20180345402
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The present invention relates to improvements to arc welding torch where lateral movement is imparted to the arcing end of the electrode in a controlled and continually adjustable manner. More specifically, improvements to the control of the movement imparted to the arching end of the electrode, and other operational aspects of arc torch operations.
Differing conditions make adjustments necessary to achieve optimum results in the welding process. In some environments, conditions may change during the course of a single weld operation. It is desirable for a torch to be re-configurable rather than requiring multiple torches. It is also desirable for adjustments to be made during the course of a single task as conditions vary in material, angle, or even surrounding environment.
Applicant has previously discussed difficulties appreciated by those skilled in the arts, and the Applicant's previous contributions to the industry with respect to aspects of rotational arc welding in PCT/US13/049700, a P.C.T. application filed in the U.S. receiving office on 09 Jul. 2013, incorporated herein in its entirety by reference.
With the foregoing and other objects in view, all of which more fully hereinafter appear, our invention comprises certain combinations, constructions and arrangement of parts and elements, and operations, sequences and steps, all as hereinafter described, defined in the appended claims and illustrated in preferred embodiment in the accompanying drawings in which:
The present invention extends the state of the art beyond that disclosed in our previous patents. Improvements involve toolless adjustment capabilities, improved design features and usability enhancements, and external control capabilities.
In prior designs, the width of the rotational path was controlled by varying the speed and direction of an electronic motor to increase or decrease the centrifugal force, or varying the length of the rotating contact tip through a swap and replace of the wand component. In the improved design, a rotor head assembly is comprised of a plurality of mating cylindrical components with offset axis and an opening through which the electrode passes. The components are rotated with respect to one another and locked into varying alignments which adjust the distance of the electrode opening from true center. This deflection of the electrode results in a change in the width of the contact tip's rotational path.
In the preferred embodiment, the rotor head assembly is manually rotated, and held in alignment through the lower rotor head component's locking pins/ball plungers which are urged via a springing component into a plurality of holes or divots in the upper rotor head component. Manually twisting the upper rotor head component thus adjusts the width of the contact tip's rotational path without the need for tools or the swapping of parts. In another embodiment, the rotation of the rotor head assembly and deflection of the electrode is accomplished via a mechanized component such as a stepper motor, solenoid, or voice-coil actuator. This allows for finer control of the contact tip's rotational path in an automated fashion.
In one embodiment, the mechanized control is connected to a computing device which further interfaces with sensors on or near the tip of the torch. The sensors detect the weld environment and adjust the torch in response to changing conditions. The sensors may be cameras and video processors, or measure the changes in the arc lighting, or heat sensors, or wind flow sensors.
A further improvement in the apparatus is the incorporation of an active electronic control and monitoring device. The previous electronics would provide signals (stepper or servo) to the motor for rotation, and would allow speed and direction control. The improved control device allows greater control over the motor such as spin delay, programmed spin patterns, digital feedback, monitoring of sensors and torch system feedback, and automated or preprogrammed responses.
The previous electronics would generate a passive signal to the motors targeting operation at certain revolutions per minute (RPM). The improved system monitors the motor's actual progress and adjusts output to maintain the required RPM, or to record and report the discrepancy there between. Many means of measuring a motor's speed and performance are known by those skilled in the arts, and no specific motor measuring apparatus, process, or method are claimed by the patent. Therefore, further details are not necessary in this specification.
The improved system allows programmed motor control signals which are customized to produce a desired spin. By varying the motor control signal, different patterns can be achieved in the tip's impelling of molten metal material. For instance, a steady control signal during rotation will generate a circular tip rotation pattern and an even deposit of material. Increasing the signal strength will increase the diameter of the rotational pattern and widen the material dispersal area. Adding a sharp increase in the control signal in phase with the motor's rotation such that the increase is cycled at the same motor position each revolution, will result in an increase in tip's force in a relevant direction and thus more material deposited in that direction. This is useful because a horizontal weld on a vertical surface can program the apparatus to impel more material to the upper side of the weld to counteract slumping toward the bottom of the weld channel.
The improvements further comprise a flexure in place of the braided copper wires and spherical bearings of the previous design. The flexure provides the flexible physical support of the electrode, allowing shielding gas to pass through, and providing an electrical contact sufficient to handle the large currents necessary in welding applications. The flexure is a disc shaped component of conductive material. The disc comprises an inner and an outer ring, the rings are joined by a plurality of arms which extend inward from the outer ring, and curve partially around the circumference of the inner ring before attaching to the outer edge of the inner ring. The arching arms allow the inner ring to flex so its plane may not be parallel to that of the outer ring.
The space between the arms allows shielding gas to pass through the flexure. The cross section of the arms is balanced between the opening size necessary for sufficient quantities of shielding gas to pass through the flexure, and the amount of arm material necessary to conduct sufficient electricity between the rings for proper welding. The joints between the arms and the rings are filleted to encourage flexure to occur in the arms.
The flexure design allows shielding gas to flow through the body of the welding torch. This means gas passes around the motor of the torch, adding cooling to the motor and the handle. This improved cooling along with the isolated outer body and a heat shield boot, allow the torch to be comfortably held for manual welding. It also reduces the complexities of counting and operating in mechanized or automated operations.
Another improvement in the apparatus includes separating the wand tip into multiple components, as the end of the wand closest to the weld may become damaged in the harsh environments. Replacing the end of the wand assembly rather than the entire wand is easier and less costly. Additionally, this allows the end of the wand to be extended or shortened by using different wand ends for different environments, allowing for further customization of the apparatus.
In another embodiment, the wand of the torch can be lengthened with one or more extensions. Adding extensions also requires the gas shielding nozzle be extended and possibly shaped differently to accommodate the movement of the tip, which will be exaggerated due to the longer wand.
In the improved torch (200), the wire (W, not indicated) still passes through a hollow shaft of the motor (128), but then passes through a rotor head assembly (300) which imparts rotational fluctuation by eccentric rotational movement to the wand (40). The wand is supported by a flexure assembly (400) which is configured to allow the rational sway that causes the rotational movement of the contact tip (52) in the gas shielding nozzle (57).
The first pattern (720) is essentially circular as a result of the first control signal (720′) being held at a steady level. Increasing or decreasing the control signal (720′) will result in a larger or smaller radius to the pattern (720). This pattern may be utilized to evenly deposit materials across a larger weld gap in a filling procedure. The second control signal (730′) is steadily varied between a high value (731′) and a low value (733′), and cycled twice for each rotation of the contact tip. The result is an increase (731) and a decrease (733) in the radius of the tip pattern (730) at two points each pass, and thus an essentially oval shape. This pattern may be utilized to deposit more materials to opposite sides of a narrower weld gap. The third control signal (740′) is steadily varied between a high value (741′) and a low value (743′), and cycled once for each rotation of the contact tip. The result is an increase (741) and a decrease (743) in the radius of the tip pattern (740) at one point, or an offset of the weld deposits to one side of the weld line. This pattern may be utilized to deposit materials off center in a location where the environment does not allow proper centering of the torch over the weld joint. One skilled in the art would appreciate that different patterns can be utilized in different environments and for achieving different effects in the welding process.
We have now described our invention in considerable detail. It is obvious, however, that others can build and devise alternate and equivalent constructions and operations which are within the spirit and scope of our invention. Hence, we desire that our protection be limited, not by the constructions and operations illustrated, and described, but only by the proper scope of the appended claims.
The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the particular proportions illustrated. Additionally, some elements illustrated in the singularity may actually be implemented in a plurality. Further, some element illustrated in the plurality could actually vary in count. Further, sonic elements illustrated in one form could actually vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.
The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US15/29828 | 5/8/2015 | WO | 00 |
