KR20220119809A - A light, low-priced extension cable of arc welding machine using CO2 gas and method of manufacturing the extension cable - Google Patents

Abstract

The present invention relates to an extension cable of an ARC welding machine using carbon dioxide gas and a manufacturing method thereof. The extension cable can reduce a production time and costs for purchasing an insulating material and prevent excessive production of signal lines by manufacturing a plurality of signal lines with the same color and marking a sign or number to distinguish the signal lines, can reduce production costs of the signal lines by using a cooper clad aluminum (CCA) conductor, which is cheaper and lighter than existing copper, and can be improved for enhancing work efficiency by decreasing tiredness of welding work.

Description

A light, low-priced extension cable of arc welding machine using CO2 gas and method of manufacturing the extension cable

The present invention relates to an extension cable used in a carbon dioxide gas welding machine, and more particularly, a gas hose connected to a power line 11, a signal line 12, and a carbon dioxide (CO2) gas container (6) from the welding machine (1). A number of, usually 8 signal lines in an extension cable (also referred to as 5 or single cable) made in a bundle of (30) are made in the same color and marked with a sign or number to distinguish them, thereby reducing production time and It can reduce the cost of purchasing insulation materials and prevent overproduction of signal lines, and reduce the manufacturing cost of signal lines by using copper clad aluminum (CCA) conductor, which is cheaper than copper and lighter in weight than conventional copper, and reduces the fatigue of welding work. It relates to an extension cable of a carbon dioxide gas welding machine and a method for manufacturing the same, which is improved so as to increase work efficiency by reducing it.

In general, the carbon dioxide (CO2) gas welding machine generates an electric arc between the continuously supplied consumable wire (welding rod) and the base material to be welded, and at the same time, to protect the molten weld, pure CO2 gas through the gas nozzle formed at the tip of the welding torch It is widely used in shipbuilding and other various industrial sites to form good welds by preventing oxidation and nitridation of weld metal by blowing out and blocking the air around the weld.

The carbon dioxide gas welding machine is composed of a welding machine (1), a wire feeding device (2), and a welding torch (4), the extension cable (5) installed between the welding machine and the wire feeding device is controlled with the carbon dioxide gas supplied from the welding machine. Signal and welding power are transmitted to the wire feeder.

However, in order to distinguish between the two power lines installed in the extension cable and a number of signal lines (usually about 8), they have been manufactured with different colors when covering the signal lines or power lines.

In particular, when producing wires for each color, the minimum production length differs depending on the thickness, but in the case of a thin signal wire, more than 10,000 meters in one color must be produced. Even so, a total of 80,000 meters had to be produced, so the inventory burden was large due to overproduction.

In addition, Teflon wire or cross-linked polyethylene (XLPE cable) is generally used for the insulation coating material, which is more than 50% more expensive than general PVC materials. Each time the color of the insulation coating material is changed during wire production, there is a production delay due to the replacement, so there is a problem in that the wire manufacturing cost increases.

In addition, since the signal line of the extension cable uses only copper, the price increases, and the operator is easily fatigued by the weight of the extension cable, thereby reducing work efficiency and productivity.

Patent Document 1: Public Utility Model Publication No. 20-2017-0004354 Patent Document 2: Registered Patent Publication No. 10-1298477 Patent Document 3: Registered Utility Model Publication No. 20-0374075 Patent Document 4: Registered Utility Model Publication No. 20-0376276

Therefore, the present invention reduces production time and manufacturing cost, prevents overproduction of electric wires, and reduces low cost and weight in consideration of the problems that occur during the manufacture of signal wires coated with insulating materials of various colors on copper used for extension cables. An object of the present invention is to provide an extension cable for a carbon dioxide gas welding machine to which a reduced signal line is applied and a method for manufacturing the same.

In order to achieve the above object, the present invention is an extension cable provided to a wire feeding device in the form of a bundle of two power lines, a plurality of signal lines, and a power cable coming from a gas hose connected to a carbon dioxide gas container and a welding machine, the The two power lines are covered with white and black insulating materials, and the plurality of signal lines uses copper clad aluminum (CCA) conductors instead of the conventional copper, and the plurality of signal lines are covered with insulating materials of the same color, An extension cable is provided, characterized in that it is printed on an insulating material to be distinguished from each other by a sign or a number.

According to an embodiment of the present invention, a plurality of signal lines used in an extension cable of a carbon dioxide gas welding machine are manufactured in the same color, a sign or a number is displayed to distinguish them, and produced using a copper clad aluminum (CCA) conductor. It can reduce time and cost of purchasing insulating material, prevent overproduction of signal lines, reduce manufacturing cost of signal lines, and reduce fatigue in welding work, thereby improving work efficiency.

1 is a schematic diagram showing the main configuration of a carbon dioxide gas welding process
Figure 2a is a photograph showing a cross section of an extension cable and a power line and a signal line in a welding cable, a gas hose and a control cable inside;
2b is a picture of color-coded power lines and signal lines in the control cable;
3 is a view showing that the signal lines of the same color of the present invention are printed so as to be divided into alphabets;
4 is a connector showing a contact point marked with the alphabet corresponding to the signal line of the present invention;

The present invention will be described in detail with reference to the accompanying drawings as follows.

1 is a schematic diagram showing the main configuration of a carbon dioxide gas welding process, a control cable formed of a gas hose 30 connected to a carbon dioxide gas container 6, a power line 11 coming out of the welding machine 1, and a signal line 12 ( 10) and an extension cable 5 provided to the wire feeding device 2 in the form of a bundle of a welding cable 20 for supplying welding current and a torch cable connected from the wire feeding device to the welding torch 4 The general form of a carbon dioxide gas welding machine is shown.

The use of carbon dioxide gas welding machines is increasing because it is possible to perform welding work in workshops such as structures, buildings, or shipbuilding places high from the ground without moving equipment by extending the extension cable for a long time.

2A is a cross-section of an existing extension cable and a photograph showing the power and signal lines in the welding cable, gas hose and control cable inside, and FIG. 2B is a black and white insulating material coated with two power lines and a different color. 8 signal lines are shown in detail.

The power line is covered with black and white insulating material with a standard conductor size of 1.25㎟ thickness, and it is a wire to control the main power such as the input motor.

In order to perform welding in a place far apart from the carbon dioxide gas welding machine, volume values such as voltage and current for welding in the wire feeder are adjusted, or an on/off operation of a switch is performed. To this end, a signal line 12 for transmitting various control signals must be connected separately from the power line 11 for supplying power between the carbon dioxide gas welding machine and the wire feeding device 2, and the signal line 12 is a standard conductor A large number of standard 0.75㎟ thick, usually covered with 8 colors, are distinguished.

This signal line 12 is installed inside the connection cable 5 connecting the carbon dioxide gas welding machine and the wire feeding device 2, and the control signal transmitted and received through the signal line includes a torch control signal indicating the start and end of welding. Signal, an inching control signal for driving the wire supply motor provided in the wire supply device, a voltage control signal for adjusting the welding output voltage, a current control signal for indicating the driving speed of the motor, and a welding torch connected to the wire supply device (4) There are a solenoid valve control signal for controlling the opening and closing of gas so that carbon dioxide gas can be supplied to the furnace, a motor control signal for rotating a wire supply motor to supply a wire, and the like.

Figure 2b shows the conventional eight signal wires 12 coated in different colors. In order to manufacture the signal wire in this way, it has high hardness and toughness in order to prevent disconnection due to repeated bending/unfolding with a covered insulation material. It is manufactured using a Teflon wire or cross-linked polyethylene (XLPE cable) insulation material having a heat resistance of 90°C or higher that can withstand heat generation due to high current of the welding cable 20.

This material is more than 50% more expensive than general PVC materials, and it is necessary to purchase it as a basic purchase lot in 8 colors, so the material purchase cost is high.

In addition, it takes a lot of time to change the color whenever the color of the insulation material is changed during wire production.

The minimum production length is applied when producing electric wires, and depending on the thickness, thousands of meters to tens of thousands of meters must be produced. .

Therefore, if there are 8 colors, 80,000 meters must be produced. In fact, one production lot of extension cables is only about 3,000 meters, so a total of 24,000 meters of signal lines 12 are required, but in reality, each The inventory burden was large due to overproduction, which required production of 80,000 meters each.

FIG. 3 shows that the insulation material of 8 wires is extruded in the same color by improving this, and alphabet codes or Arabic numerals are printed on the surface of each wire for easy identification when using a signal wire.

Since the power line 11 is normally used by dividing it into black and white, it is used as it is in consideration of the position of the existing user.

In addition, the signal line 12 that transmits various signals such as welding speed, voltage, and current is used as a low DC power source converted through an inverter circuit, so it is a CCA conductor having good conduction performance instead of pure copper which is expensive and relatively heavy. By using , there is an advantage in that the manufacturing cost of the signal line can be lowered and the weight can be reduced.

If we look at this in detail, there is no problem in maintaining performance and function even if all the conductors used for the 8 signal lines are manufactured with CCA conductors. It is possible to maximize production efficiency such as production prevention.

That is, if all 8 strands of 0.75㎟ signal wire are produced with CCA conductors of 10,000 meters each, the weight is reduced by 320 kg as shown in Tables 1 and 2 below, compared to the case of copper production, and the production cost is reduced by about 1.02 million won.

weight comparison wire
cross-sectional area wire thickness
(Completed outer diameter) 1 meter weight
(one finished product) 8 strands
weight ten thousand meters
production weight total weight reduction
(10,000 meters production) Copper 0.75㎟ 2.1mm 9.2g 73.6g 736 kg - CCA 0.75㎟ 2.1mm 5.2g 41.6g 416 kg -320kg reduction

Comparison of production cost wire
cross-sectional area wire thickness
(Completed outer diameter) 1 meter price
(one finished product) 8 strands
price ten thousand meters
production price total cost reduction
(10,000 meters production) Copper 0.75㎟ 2.1mm 98 won 874 won 774 million won - CCA 0.75㎟ 2.1mm 84 won 672 won 672 million won -102 million won

In addition, when the signal line 12 is covered with eight colors of insulating material, the replacement time according to the color change of the insulating material in the wire production process depends on the machine capability, but takes about 30 minutes. Therefore, considering the 8 colors, 240 minutes and 4 hours loss occurs, but when making and marking signal lines with the same color, the wire marking time is less than 5 minutes for both the manual roller method and the automatic computer printing method. It takes about 40 minutes in total.

Therefore, considering the time to change the print content from the time to change the color of the insulating material, the time saving effect is about 200 minutes.

4 shows a connector 40 for assembling by connecting the 8 signal lines 12 of the present invention and 2 black and white power lines 11, and the connector 40 includes a power line 11 2 contacts for wiring and 7 contacts for connecting signal lines 11 for transmitting signals for controlling welding operations (one signal line not connected to the contact is an extra signal line for use when necessary) have.

The connector has 9 wiring pins, and as shown in FIG. 4, pin codes that can be referenced for wiring are marked on each pin from English alphabets A to I, and alphabets corresponding to 7 pins from A to G are printed on each pin. Connect the signal lines and connect the power lines to H and I to make a connection cable assembly.

In addition, the extension cable 5 uniformly distributes the signal line 12, the power line 11, and the welding cable 20 around the gas hose 30 so that the flexibility of bending and bending is kept constant in all directions. .

1: welding machine 2: wire feeding device
3: remote controller (remote control) 4: welding torch
5: extension cable 6: carbon dioxide gas container
10: control cable 11: power line
12: signal line 20: welding cable
30: gas hose 40: connector

Claims (3)

In the extension cable provided to the wire feeding device in the form of a bundle of two power lines, a plurality of signal lines, and a welding cable from a gas hose connected to a carbon dioxide gas container and a welding machine,
The two power lines are covered with white and black insulating materials,
The plurality of signal lines are coated with an insulating material of the same color on a copper clad aluminum (CCA) conductor, and are printed on the insulating material to be distinguished from each other by a sign or a number.
According to claim 1,
In the connector for connecting the two power lines and the plurality of signal lines, a plurality of contacts connected to the plurality of signal lines are marked with the same sign or number as the sign or number printed on the signal line, and the extension cable is characterized in that it is connected to match each other.
Extruding and covering a copper clad aluminum (CCA) conductor with an insulating material of the same color in producing a signal line used for an extension cable;
displaying a sign or number to distinguish the coated insulating material from each other;
preparing a plurality of printed signal lines to be distinguished and two power lines black and white;
preparing a connector having contacts marked with the same symbols as those printed on a plurality of signal lines and contacts connected to two power lines;
wiring so that the sign of the signal line matches the sign of the connector contact and also the two power lines;
A method of manufacturing an extension cable, comprising: uniformly distributing a signal line connected to a connector, a power line, and a welding cable around a gas hose.

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