DE102008014814B4 - hosepack - Google Patents

Abstract

Hose package of an arc welding or cutting torch with a plurality of current-carrying lines (25, 44) which are arranged in a channel coaxially about a central channel (22, 23, 41), which is provided for guiding a welding wire (21), characterized in that the lines (25, 44) comprise copper-coated aluminum wires.

Description

The The invention relates to a hose assembly of an arc welding or Cutting torch with a plurality of current-carrying lines according to the preamble of claim 1.

State of the art

A hose package of coaxial construction with the features of the preamble of claim 1 is known from EP 0 076 390 A1 known.

Arc welding and cutting torch are Known in the art for a long time. Such welding and cutting torches can for manual or automated welding be educated. Arc welding and cutting torch for manual Use usually have a base and a handpiece, which over a Hose package are connected together. For manual arc welding and cutting torches it is necessary the handpiece preferably to be able to move freely. In particular, the material has to have a good mechanical resistance to change have at bending and torsional load.

Arc welding and cutting torch for automated welding are common like robots built with a movable robotic arm that the to be welded Areas starts. A hose package is between a base and an effector intended. In automated welding, in favor of welding speeds often worked with high accelerations of the robot arm. The hoses swing in certain limits free and are doing high mechanical loads exposed.

For welding are high levels of power required via power cable from the base to the handpiece must be transported. Due to the good electrical conductivity is used for power cables of arc welding and cutting torch used in the prior art predominantly copper. A another property of copper is its good thermal conductivity, which makes it possible to remove the heat generated by the resistance quickly.

Farther Fulfills Copper's requirements for mechanical properties. In the state the technology is common to run the power cables as strands.

Farther It is known that electrical conductors are made of all metals can be.

Furthermore, a hose package is also from the DE 15 15 145 A known. The welding cable contains a sheath of flexible synthetic material with a perfectly smooth inner wall to guide the welding wire. This envelope is surrounded by a coiled copper wire bundle or also aluminum wires for conducting the current. The wire bundle is surrounded on the outside by a rubber layer. To strengthen the cable in terms of tensile loads, the conductor may be surrounded by a steel braid.

The DE 85 09 258 U1 discloses a welding line in which a part of the current-carrying leads is made of aluminum and another part of the electrical leads is made of copper. In this case, an inner conductor made of aluminum to which an outer conductor is stranded consisting of copper.

The in copper packages currently used electrical conductors made of copper have the disadvantage that the electrical conductors up to 2/3 of the Make total weight of the hose package and the handle on Time-consuming can be. The load on the hose assemblies for automated welding increases also with the lethargic Mass of the hose package.

From the DE-AS 20 52 462 For example, a method of continuously producing wires from an aluminum core and a copper cladding is known. Such copper-clad aluminum wires are said to have the advantage of combining the relatively low specific gravity and economy of the aluminum with the good electrical properties of the copper.

Finally, out of the US 2006/010 23 68 A1 a copper-plated aluminum cable is known, which has a core made of aluminum, which is coated with an intermediate layer of copper, wherein the intermediate layer is in turn coated with a coating of nickel. This is to provide a compromise between cable conductivity, breaking load and flexibility so that these cables can pass through non-linear and relatively long ducts without the risk of damage or jamming.

It is therefore an object of the invention, a hose package for a Arc welding and cutting torch indicate that opposite the known from the prior art hose packages with copper cables is much lighter, but comparable positive mechanical Properties such as alternating strength during bending and torsional loading having.

Presentation of the invention

These Task is solved by a hose package according to the claim 1. Advantageous embodiments are described in the subclaims.

Of the Use of copper-clad aluminum wire as a live conductor the hose package has the advantage that on the one hand a weight saving achieved on the other hand, but an occurrence of high temperatures at the transitions between the ladders and the connections is not observed. Presumably, this is due to the fact that the inherently higher contact resistance between Aluminum and the respective connection due to the use of Copper on the aluminum wire is significantly reduced and so on achieving a Weight reduction the electrical and mechanical properties of the electrical conductor compared to the use of conventional Copper conductors are largely retained.

It it is understood that according to a preferred embodiment of the invention all live Lines each conductor designed as copper-coated aluminum wires are. It can the individual conductors in the form of individual wires, strands or the like be educated.

Besides It has also been shown that the use of copper-plated aluminum wires at the hose packages according to the invention much cheaper is. This is due to the fact that the processing by a simplified drawing process considerably is simplified.

The connections of the hose package can with the one or more live Cables are connected by means of crimp connection.

A However, preferred variant emphasizes that the current-carrying Cables with the copper-coated aluminum wires by means an ultrasonic welding process to the connections the hose package are connected.

there can the outer strand the current-carrying Conduction of the hose package directly closed with a copper sleeve become. The advantage of this connection method is that lower contact resistance and so that lower temperature increases at the transition point can be achieved. This Ultrasonic welding process Can work with both aluminum wires as with aluminum wires, which on the outer jacket a copper layer, are used. It still has shown that the strength of the terminals or the sleeves when Use of the ultrasonic welding process significantly increased is opposite the strength of a crimp connection. As connections can both copper sleeves as well as steel sleeves be used.

From Advantage, the copper layer of the aluminum wire has a thickness from 1 to 100 μm on. Because of this measure An optimization of the copper-coated aluminum wire is ensured in terms of weight savings with the lowest possible contact resistance.

Also it has been found that the use of hose packages has been live Lines that are designed as strands, and their individual wires aluminum contain the requirements for use in arc welding and cutting torch fulfill.

Inventive hose packages have the advantage of facing hose packages with copper pipes are considerably lighter and thus easier to handle. In spite of for transmission the required increased necessary aluminum volume is the total weight of hose packages, which are manufactured with aluminum strands, considerably less than the total weight of conventional Cable assemblies.

With the hose package according to the invention is a long-standing prejudice of professionals who overcome aluminum cables due to their poorer line characteristics and due to their Bending and breaking behavior not for use in hose packages have considered.

By the execution the aluminum line is a strand with relatively fine individual wires the bending and torsional load of the individual wires compared to a wire with a larger cross-section lower.

For the individual wires has pure aluminum with the purities of Al 99 to Al 99.9 proved to be particularly suitable. Nevertheless, it is possible to use aluminum alloys to use.

advantageously, At least one composite line is provided, the individual wires copper-coated aluminum or an aluminum-containing alloy and single wires of copper or of a copper-containing alloy. Surprisingly it was found that such composite lines heat dissipation significantly improve the lines, the overall cost of the hose package still cheaper compared to pure copper wires are.

Advantageously, the line has at least four individual strands, which are beaten around a core strand. Such a constructed line has high flexibility, even with large cable cross-sections.

advantageously, Each individual strand and / or the core strand consists of at least 20 Individual wires. This increases the flexibility and reduces the risk of line breakage.

In an advantageous embodiment of the invention, the individual wires have a Diameter from 0.05 mm to 0.5 mm. Particularly preferred a diameter of 0.15 mm. With such single wire diameters the necessary line parameters can be achieved.

advantageously, is the lay length of the Strands of 15 mm to 200 mm, with 40 mm to 60 mm being particularly preferred are. Such stroke lengths improve the mechanical properties of the hose package.

According to the invention are several live ones Cables arranged coaxially around a central channel. This allows the Combination of several functions the hose package has to fulfill with a smaller number of individual hoses. It is also possible, synergy effects to achieve, for example, when the central channel is a cooling medium leads. Then the heat-emitting current-carrying line simultaneously active with the cooling medium chilled become.

advantageously, is at least one extra Control power line provided. This allows functions of the Welding device by means of of the handpiece control in a simple way.

Especially It is advantageous if at least two channels for conducting a medium and at least two current-carrying Lines are provided. As in the case described above brings the Combination of media line and live line positive effects regarding the efficiency of the power line. The provision of at least two channels with live Lines, where the current-carrying Lines can also be arranged centrally and directly from the medium to be flowed around can, elevated the surface the lines and thus their heat dissipation. About that In addition, with constant flexibility of the cross section of the lines climb. Overall, it is thus possible to increase the transferable performance of the hose package increase.

Especially It is advantageous if a channel for guiding a welding wire is provided. Leave it the welding wire in a base station of the welder in comparatively large quantities stockpile and the welding wire is passed through the hose package to the handpiece as required.

According to the invention is a channel for the live ones Lines provided. Especially with a coaxial arrangement It may be necessary to consider the individual functions of a hose fulfill must, spatially to separate from each other, for example, because the current-carrying line another potential than one possibly in the hose package to be transported welding wire has.

Especially It is advantageous if all channels are coaxial are arranged. this makes possible the most efficient use of existing space and allows better manageable hose packages with a smaller diameter.

Surprisingly An arrangement has proven to be advantageous in which the channel with the current-carrying Lines surrounds the channel for conducting the medium and / or the Channel for guiding the medium, the channel for guiding the welding wire surrounds. Thus, the media channel for cooling the welding wire channel serve and at the same time for cooling the channel with the current-carrying Management.

When suitable medium for the channels a polymer has been found. Polymers can meet a wide variety of requirements fulfill and have proven themselves in continuous use.

Prefers the medium consists of a gas or a liquid. This can be the process gas, ie inert gas welding around the Inert gas or a liquid act, for example for cooling of the handpiece.

advantageously, has the current-carrying line at one end to a terminal by means of a crimp connection with the current-carrying Line is connected. Surprisingly It has been shown that such crimping a permanent reliable and secure connection between live line and connection produce.

alternative or additionally it is also possible that a weld the live line with a connection or a wire end ferrule by means of ultrasound. It has been shown that the copper-plated aluminum wires are not just good over Crimp connections with connections connect, but also by ultrasonic welding. in the The last case results in the connecting surfaces then virtually similar Materials that are basically add better to let.

Brief description of the drawings

Further Objectives, advantages, features and applications of the present Invention will become apparent from the following description of several embodiment based on the drawings. All are described and / or illustrated illustrated features for itself or in any meaningful combination the subject of the present Invention, also independent from their summary in the claims or their dependency.

1 a cross section through a standard hose package;

2 a cross section through an embodiment of a hose package according to the invention;

3 an embodiment of a so-called power-water cable;

4 a longitudinal section through an inventive power cable;

5 a cross section through the cable 4 along the line AA;

6 a perspective view of a stranded wire.

1 showed a schematic representation of a conventional hose package 1 , as used, for example, in arc welding or -schneidbrenner. The hose package 1 sums in the embodiment chosen here in an outer tube 2 several individual tubes together and leads them from a base, not shown, to a handpiece, also not shown, of the welder or from a base of an automated welder to an effector.

The hose package 1 has a coolant supply hose 3 in which a coolant from the base to the handpiece or effector is required inside. Furthermore, a process gas hose 4 provided within which the process gas flows to generate a protective gas atmosphere. In addition, a wire feed hose 5 provided, a welding wire 6 within one in the wire feed hose 5 provided wire feed spiral 7 transported. Furthermore, a control line 8th provided by means of which control signals are transmitted from the handpiece or the effector to the base.

Furthermore, a so-called power-water cable 9 intended. Inside a hose 10 the power-water cable 9 is a live line 11 provided, which will be described in more detail below. Between the hose 10 and the live line 11 is a channel 12 intended for the coolant return. This has the advantage that the coolant on the coolant return at the same time the current-carrying line 11 can cool, which heats up strongly due to the high welding performance required.

Inside the hose package 1 can be provided more lines.

2 shows a further embodiment of a hose package according to the invention 20 , This in 2 illustrated hose package 20 has a substantially coaxial arrangement of the individual elements. Inside the hose package 20 becomes a welding wire 21 inside a wire feed spiral 22 guided. The wire feed spiral 22 surrounding is a gap 23 provided, which serves to convey the process gas. For gas-tight sealing is a hose 24 intended. The hose 24 consists of an elastic polymer. On the hose 24 are live cables 25 on and in black illustrated control lines 26 , The live cables 25 have the inventive strand structure, the in 5 will be explained in more detail. The hose package is held together 20 from an outer tube surrounding all hoses 27 , outer tube 27 and hose 24 form between them an annular channel for the current-carrying lines 25 and the other lines. The hose package 20 may be part of a larger hose package in which further hoses are provided for different purposes, such as coolant hoses and the like.

3 shows the power water cable 9 out 1 in an enlarged view.

The power water cable 9 has an outer tube 30 which is waterproof to conduct the cooling medium. Instead of water, any other fluid known from the prior art can also be used as the cooling medium. In a concentric arrangement is located in the middle of the power-water cable 9 the live line 11 ,

The live line 11 is designed as a strand of single wires 32 consists. The single wires 32 the strand 11 consist of aluminum or an aluminum alloy. Pure aluminum with purities Al 99 to Al 99.9 has proven to be particularly suitable. These wires 32 are coated or coated with a copper layer, which significantly reduces the contact resistance. The thickness of the layer is between 1 and 100 microns.

The single wires 32 Have a single wire diameter of 0.1 to 0.3 mm. In a strand are bundled in about thirty individual wires, with strands of up to 100 individual wires have been found to be suitable in terms of elastic properties. The cross section of such a strand is about 10 mm ² , whereas the known from the prior art copper strands have a cross section of, for example, 6 mm ² . In the case of aluminum, cross sections up to about 30 mm ^{2 are} conceivable without further ado. The lay length of the strands themselves is about 60 mm, but may be between 15 mm and 200 mm, depending on the strand cross section.

at So-called interconnections can also copper-coated individual wires made of aluminum or an aluminum alloy and single wires Copper or a copper alloy can be used in a stranded wire.

In a further embodiment, not shown, the current-carrying line 11 a plurality of strands, wherein a core strand is provided to the other strands 31 are beaten.

It is possible to have several of the in 3 provided power-water cables within a hose package. Particularly preferred are two power water cables have proven, one of which is responsible for the coolant inlet and one for the coolant flow. Thus, it is possible to divide the current-carrying lines, which on the one hand increases the flexibility of the hose package and on the other hand improves the cooling performance of the coolant on the current-carrying lines. Such arrangements are known in the art.

4 shows a longitudinal section through a power cable 40 with a connection 35 to a base of the welder. The connection 35 has a hex nut 36 for correctly connecting the power cable 40 to the base. Furthermore, a ferrule 37 and a ferrule 38 provided for receiving the end of the line 40 serve.

Furthermore, control lines 43 shown by means of separate plug 39 be connected to the base. The control lines 43 be in front of the end area of the power cord 40 from an outer shell 46 of the power cable 40 led out.

Inside the tube 40 created by the crimp a hollow area 41 from the connection 35 to the opposite end of the pipe 40 which is completely sealed. The area 41 may be gas tight and / or liquid tight.

5 shows a cross section through the power cable along the section line AA according to 4 , of the power cable 40 which is inside the area 41 which is usable for conducting either a cooling medium or a process gas.

The inner area 41 is through a hose 42 sealed. On the outside of the hose 42 several lines are arranged with different functions. Dotted hatched are control lines 43 for controlling functions of the welder. Shown in shaded light are live cables 44 , which are also designed as strands. The areas 45 does not have any special function. The areas 45 can z. B. filled with a filler or with plastic ropes. The wires 43 . 44 and the areas 45 are with a hose 46 cast around.

The 6 shows a perspective view of the current-carrying line 11 from the 1 and 4 , The single wires 32 are around a core wire 47 beaten. Shown is a half blow. The lay length d, ie the length running in the direction of line, over which a single wire 32 once completely around the core line 47 is wound, is 60 mm. However, the lay length may vary from 20 mm to 120 mm, depending on the thickness of the pipe 11 and the thickness of the individual wires 32 , Such a running line 11 has the advantage that it is resilient in many ways. The administration 11 can be twisted in both directions, curved and also stretched or compressed. In addition, the elasticity of such a line is substantially higher than in a line made of solid material with the same cross-section.

1

hosepack

2

outer tube

3

Coolant supply hose

4

Process gas hose

5

Wire spiral conveyor

6

welding wire

7

Wire spiral conveyor

8th

control line

9

Electricity Water Cable

10

tube

11

live line

12

channel

20

hosepack

21

welding wire

22

Wire spiral conveyor, channel

23

channel

24

tube

25

wire, management

26

control line

27

outer tube

30

outer tube

32

individual wires

35

connection

36

Hex nut

37

end sleeve

38

ferrule

39

plug

40

power cable

41

Area

42

tube

43

control lines

44

live cables

45

Area

46

tube

47

core wire

d

lay length

Claims (18)

Hose package of an arc welding or cutting torch with several live cables ( 25 . 44 ), which in a channel coaxially around a central channel ( 22 . 23 . 41 ) arranged to guide a welding wire ( 21 ) is provided, characterized in that the lines ( 25 . 44 ) have copper-coated aluminum wires. Hose pack according to claim 1, characterized the copper layer has a thickness of 1 to 100 μm. Hose package according to claim 1 or 2, characterized in that the lines ( 25 . 44 ) at least one strand ( 11 . 25 . 44 ) whose individual wires ( 32 ) consist of copper-plated aluminum wires. Hose package according to one of the preceding claims, characterized characterized in that the aluminum wire is made of aluminum or a Aluminum alloy exists. Hose package according to one of the preceding claims, characterized in that at least one composite line ( 11 . 25 . 44 ), the individual wires ( 32 ) of copper-clad aluminum or a copper-clad aluminum-containing alloy and individual wires of copper or a copper-containing alloy. Hose pack according to one of the preceding claims, characterized in that the current-carrying lines ( 11 . 25 . 44 ) have at least four individual strands which are beaten around a core strand. Hose package according to claim 6, characterized in that each individual strand ( 11 . 25 . 44 ) and / or the core strand of at least 20 individual wires ( 32 ) consists. Hose package according to one of the preceding claims, characterized in that the individual wires ( 32 ) have a diameter of 0.05 mm to 0.5 mm, preferably 0.15 mm. Hose package according to one of claims 6 to 8, characterized in that the lay length (d) of the strands ( 11 . 25 . 44 ) of 15 mm to 200 mm. Hose package according to one of claims 6 to 8, characterized in that the lay length (d) of the strands ( 11 . 25 . 44 ) Is 40 mm to 60 mm. Hose pack according to one of the preceding claims, characterized in that at least one additional control line ( 43 ) is provided. Hose pack according to one of the preceding claims, characterized in that at least two channels for conducting a medium and at least two current-carrying lines ( 25 . 44 ) are provided. Hose package according to one of the preceding claims, characterized characterized in that all channels are arranged coaxially. Hose pack according to claim 13, characterized in that the channel with the current-carrying lines ( 25 . 44 ) the channel ( 23 ) surrounds the medium and / or that the channel ( 23 ) for conducting the medium the channel ( 22 ) for guiding the welding wire ( 21 ) surrounds. Hose pack according to one of the preceding claims, characterized in that the channels ( 23 ) are separated by a polymer. Hose package according to one of claims 12-15, characterized characterized in that the medium is a gas or a liquid is. Hose pack according to one of the preceding claims, characterized in that the current-carrying lines ( 25 . 40 . 44 ) at one end a connection ( 35 ), which by means of a crimp connection with the current-carrying lines ( 25 . 40 . 44 ) connected is. Hose pack according to one of the preceding claims, characterized in that a welding of the current-carrying lines ( 25 . 44 ) with a connection ( 35 ) or a wire end ferrule ( 37 ) by means of ultrasound.