Description:FIELD OF THE INVENTION

[0001] The present invention relates to an adaptable welding assistive device that is capable of securely holding an electrode during a welding process for enabling a user to perform welding with enhanced control and continuously monitoring length of the electrode during welding and adjusting the electrode’s position to ensure uninterrupted feed and consistent welding quality.

BACKGROUND OF THE INVENTION

[0002] Welding is a critical process in many industries, requiring precision and consistency to create strong, reliable joints. However, traditional welding methods can be challenging, as they demand constant attention to electrode positioning, the length of the electrode, and ensuring a steady feed during the welding operation. Maintaining optimal shielding gas flow and protecting the operator from sparks, heat, and fumes adds to the complexity of the process. Additionally, managing these elements manually leads to inconsistencies and increased risk for the welder.

[0003] To overcome these challenges, there is a growing need for an innovative solution that improves the efficiency, safety, and control of the welding process. The present invention seeks to provide a device that integrates automation and monitoring systems to support the welder in achieving high-quality, consistent welds. By securing the electrode, monitoring its length in real-time, and adjusting its position automatically, this device ensures continuous electrode feed and reduces the risk of welding defects. Furthermore, by incorporating features such as controlled gas flow and spark protection, the invention aims to enhance safety and ease of use for the operator.

[0004] US20220388089A1 discloses a projection welding device and an electrode cleaning method for the same with which it is possible to keep a stud holding hole formed in a welding electrode clean. A projection welding device welds a stud to a workpiece by holding the stud using a second electrode, bringing the stud into contact with the workpiece, and causing a welding current to flow through the second electrode, wherein the second electrode includes a stud holding hole which extends from a cap opening formed in the distal end, to a bottom portion formed on the base end side, and at least one lateral hole which extends from a side wall opening formed in a side wall to the bottom portion, and the projection welding device is provided with a stud supply device which ejects air into the stud holding hole from the cap opening of the second electrode.

[0005] US20240051056A1 discloses about an arc welding torch device with a consumable electrode. The electrode in the arc welding torch device being guided in an exchangeable wire core, a guide element surrounding the wire core and designed as an exchangeable wear part. To reduce the risk of kinking of a welding wire of an arc welding torch device melting in the welding process, a kink protection means protruding from the arc welding torch device is passed through an outer end cap of the arc welding torch and arranged between the outer end cap of the arc welding torch and wire feeding means for the welding wire in which the welding wire is guided is proposed.

[0006] Conventionally, many devices have been developed to assist with the welding process, such as electrode holders, gas flow regulators, and spark protection mechanisms. While these devices offer some degree of support, they often fail to address the challenges of maintaining consistent electrode feed and ensuring precise control during the welding operation. Furthermore, these existing devices do not typically integrate real-time monitoring or automatic adjustment of the electrode’s position, leading to potential inconsistencies in weld quality and increased manual effort for the user.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that not only ensures secure electrode handling, but also incorporates real-time monitoring and automatic adjustments to electrode’s position. The device improves welding precision, maintain consistent feed, and enhance overall welding quality. Additionally, the developed device provides enhanced safety features, such as effective spark protection and controlled gas flow, to assist the welder in performing the task more efficiently and with greater ease.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that securely holds an electrode during a welding process for enabling a user to perform welding with enhanced control and continuously monitoring the length of the electrode during welding and adjusting the electrode’s position to ensure uninterrupted feed and consistent welding quality

[0010] Another object of the present invention is to develop a device that provides a means for supplying a controlled flow of inert gas to the welding area, providing a protective shield for the weld pool to prevent contamination and ensure high-quality welding results.

[0011] Yet another object of the present invention is to develop a device that protects the user from sparks and heat during welding, directing sparks away from the user’s face for enhanced safety and comfort.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to develop an adaptable welding assistive device that provides a means to securely hold an electrode during the welding process, allowing a user to perform welding with improved control and also continuously monitors the length of the electrode and adjusts the electrode’s position to ensure a steady feed and maintain consistent welding quality.

[0014] According to an embodiment of the present invention, an adaptable welding assistive device, comprises of an elongated body having a proximal and distal end, the proximal end is integrated with a handle that is accessed by a user for acquiring a grip on the body in view of holding the body for welding purpose, a pair of inverted U-shaped motorized clamps arranged at the distal end for engaging an electrode to be utilized in performing the welding, wherein an artificial intelligence-based imaging unit installed at the distal end to determine dimensions of the electrode positioned in vicinity of the distal end, a motor linked with each of the clamps to acquire a grip on the electrode while the user is performing welding using the electrode, an inlet port integrated at the proximal end for connecting a conduit connected with an inert gas cylinder for supplying inert gas at the distal end via an electronically controlled nozzle integrated at the distal end to aid the user in performing welding, an ultrasonic sensor integrated at the distal end and synced with the imaging unit for monitoring length of the electrode utilized in the welding, multiple motorized rollers integrated on inner periphery of the clamps to rotate for translating the electrode in a downward direction to aid in continuity of the welding process, an expandable plate arranged at mid portion of the body to get expanded for restricting flames or sparks generated from the welding process from reaching the user, an air blower is arranged at lower portion of the plate to rotate for directing the sparks away from the user’s face, a glass shield is assembled on upper portion of the plate for allowing the user to visualize the welding process without any discomfort and a soft cushioned layer is fabricated on the handle for providing comfortable experience to the user while holding the body.

[0015] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an adaptable welding assistive device.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0018] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0019] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0020] The present invention relates to an adaptable welding assistive device that is capable of securely holding an electrode during a welding process for enabling a user to perform welding with enhanced control and continuously monitoring the length of the electrode during welding and adjusting the electrode’s position to ensure uninterrupted feed and consistent welding quality.

[0021] Referring to Figure 1, an isometric view of an adaptable welding assistive device is illustrated, comprising an elongated body 101 integrated with a handle 102 that is accessed by a user for acquiring a grip on the body 101 for welding purpose, a pair of inverted U-shaped motorized clamps 103 arranged at the body 101, wherein an artificial intelligence-based imaging unit 104 installed at the body 101, an inlet port 105 integrated at the body 101, an electronically controlled nozzle 106 integrated at the body 101, an ultrasonic sensor 107 integrated at the body 101, multiple motorized rollers 108 integrated on inner periphery of the clamps 103, an expandable plate 109 arranged at mid portion of the body 101, an air blower 110 is arranged at lower portion of the plate 109 and a glass shield 111 is assembled on upper portion of the plate 109.

[0022] The proposed device herein comprises of an elongated body 101 having a proximal and distal end, wherein the proximal end is integrated with a handle 102 that is accessed by a user for acquiring a grip on the body 101 in view of holding the body 101 for welding purpose. The body 101 is preferably fabricated from a lightweight yet durable material, such as aluminum alloy, carbon fiber-reinforced polymer (CFRP), high-strength thermoplastics but are not limited to, ensuring that the body 101 is both portable and capable of withstanding the high temperatures and mechanical stresses encountered during welding. A soft cushioned layer is fabricated on the handle 102 for providing comfortable experience to the user while holding the body 101.

[0023] A pair of inverted U-shaped motorized clamps 103 are arranged at the distal end that are accessed by the user for engaging an electrode to be utilized in performing the welding. An inbuilt microcontroller associated with the device activates an artificial intelligence-based imaging unit 104 installed at the distal end to determine dimensions of the electrode positioned in vicinity of the distal end. The imaging unit 104 comprises of an image capturing arrangement including a set of lenses that captures multiple images of the electrode, and the captured images are stored within a memory of the imaging unit 104 in form of an optical data.

[0024] The imaging unit 104 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and are further transmitted to the microcontroller. The microcontroller processes the received data and determines dimensions of the electrode.

[0025] The microcontroller actuates a motor linked with each of the clamps 103 to acquire a grip on the electrode while the user is performing welding using the electrode. The motor used herein is a DC (Direct Current) motor that consists of a stator which provides a constant magnetic field and a rotor that rotates when current is applied. The rotor contains armature windings connected to a commutator, which ensures the direction of current through the windings changes as the rotor spins, maintaining continuous rotation. Carbon brushes maintain electrical contact between the power source and the commutator.

[0026] When the microcontroller supplies current to the motor, the interaction between the magnetic field of the stator and the current in the rotor windings generates a torque that causes the rotor to spin. This rotational motion is transferred through a gear mechanism, which converts it into linear motion to actuate the clamps 103. The microcontroller controls the motor's speed and torque by varying the current, enabling precise grip adjustments for holding or releasing the electrode securely.

[0027] An inlet port 105 is integrated at the proximal end that is accessed by the user for connecting a conduit connected with an inert gas cylinder for supplying inert gas at the distal end via an electronically controlled nozzle 106 integrated at the distal end to aid the user in performing welding. The inert gas supply means relies on controlled fluid dynamics and electronic actuation. The inlet port 105 at the proximal end serves as a connection point for a conduit linked to an inert gas cylinder, which normally contains gases like argon or helium used in welding.

[0028] When the means is activated, the inert gas flows through the conduit towards the electronically controlled nozzle 106 regulated by an electronic actuator controlled by the microcontroller, which opens or adjusts the nozzle 106 based on welding requirements. This ensures a precise flow of gas is delivered around the welding zone. The inert gas forms a protective shield 111 over the weld pool, preventing contamination from atmospheric gases like oxygen or nitrogen and ensuring a clean, high-quality weld. The microcontroller adjusts the nozzle 106 dynamically to maintain optimal gas flow during the welding process, enhancing efficiency and precision.

[0029] An ultrasonic sensor 107 is integrated at the distal end and synced with the imaging unit 104 that is activated by the microcontroller for monitoring length of the electrode utilized in the welding. The ultrasonic sensor 107 consists of a transmitter that emits ultrasonic waves and a receiver that detects the waves reflected back from an object. When activated by the microcontroller, the transmitter generates ultrasonic pulses directed towards the electrode.

[0030] These waves reflect back upon hitting the electrode’s surface, and the receiver captures the returning waves. A timing circuit calculates the time taken for the waves to travel to the electrode and back, which is used to determine the electrode’s distance. The microcontroller processes this information to monitor changes in the electrode’s length during welding, ensuring precise control over the electrode's position and continuity in the welding process.

[0031] Based on which the microcontroller actuates multiple motorized rollers 108 integrated on inner periphery of the clamps 103 to rotate for translating the electrode in a downward direction to aid in continuity of the welding process. The rollers 108 operate on the principle of rotational motion transferred from the motor through a gear mechanism. Each roller 108 is mounted on the inner periphery of the clamps 103 and is powered by a motor linked to the microcontroller that controls the rotation. The rollers 108 are made of durable, heat-resistant materials like steel or rubber, ensuring they is able to withstand the high temperatures generated during welding.

[0032] When the microcontroller activates the motor, the rotational motion is transmitted to the rollers 108, causing them to spin. As the rollers 108 rotate, they grip and translate the welding electrode in a downward direction, ensuring the electrode maintains proper contact with the workpiece and continues feeding as needed for a consistent and uninterrupted weld. The controlled movement of the rollers 108 helps regulate the electrodes positioning, contributing to the efficiency and precision of the welding process.

[0033] An expandable plate 109 is arranged at mid portion of the body 101 that is actuated by the microcontroller to get expanded for restricting flames or sparks generated from the welding process from reaching the user. The expandable plate 109 is integrated with a drawer arrangement that includes sliding racks and rails, such that the plate 109 is mounted over the racks that are electronically operated by the microcontroller for moving over the rails. Such that the microcontroller actuates the drawer arrangement.

[0034] The drawer arrangement is powered by a DC (direct current) motor that is actuated by the microcontroller by providing required electric current to the motor. The motor comprises of a coil that converts the received electric current into mechanical force by generating magnetic field, thus the mechanical force provides the required power to the racks to provide sliding movement to the plate 109 to get expanded for restricting flames or sparks generated from the welding process from reaching the user.

[0035] An air blower 110 is arranged at lower portion of the plate 109 that is actuated by the microcontroller to rotate for directing the sparks away from the user’s face. The air blower 110 consists of a motor connected to a blades housed in a casing. The motor, controlled by the microcontroller, drives the blades to rotate at high speed. As the blades spin, they create a pressure differential, drawing air into the blower 110 and forcing it out through the air outlet.

[0036] This airflow is directed towards the welding area, pushing sparks, smoke, and hot gases away from the user’s face. The microcontroller regulates the blower’s 110 speed and direction, ensuring efficient control of airflow to maintain a safe working environment by preventing sparks from reaching the user. Further, a glass shield 111 is assembled on upper portion of the plate 109 for allowing the user to visualize the welding process without any discomfort.

[0037] The device is associated with a battery for providing the required power to the electronically and electrically operated components including the microcontroller, electrically powered sensors, motorized components and alike of the device. The battery within the device is preferably a lithium-ion-battery which is a rechargeable battery and recharges by deriving the required power from an external power source. The derived power is further stored in form of chemical energy within the battery, which when required by the components of the device derive the required energy in the form of electric current for ensuring smooth and proper functioning of the device.

[0038] The present invention works best in the following manner, where the elongated body 101 as disclosed in the invention is developed to be gripped by the user while conducting welding. The inverted U-shaped motorized clamps 103 at the distal end securely hold the electrode during the welding process. These clamps 103 are actuated by motors which are controlled by the microcontroller that ensures precise grip and positioning of the electrode, allowing the user to focus on the welding task without worrying about electrode stability. The imaging unit 104 that captures and processes images around the electrode, determining its dimensions and ensuring proper alignment for optimal welding. Additionally, the ultrasonic sensor 107 monitors the electrode's length in real time, and based on this data, the motorized rollers 108 on the clamps 103 automatically translate the electrode in a downward direction, ensuring continuous feed and a consistent welding arc. Inert gas is supplied through the conduit from the gas cylinder connected to the electronically controlled nozzle 106 at the distal end, providing the necessary shielding gas to prevent contamination of the weld. The expandable plate 109 and air blower 110 protect the user by directing sparks away from the face and ensuring a safe working environment. The air blower 110, powered by the motor and controlled by the microcontroller, effectively directs the sparks and hot gases away from the user’s face.

[0039] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , C , Claims:1) An adaptable welding assistive device, comprising:

i) an elongated body 101 having a proximal and distal end, wherein said proximal end is integrated with a handle 102 that is accessed by a user for acquiring a grip on said body 101 in view of holding said body 101 for welding purpose;
ii) a pair of inverted U-shaped motorized clamps 103 arranged at said distal end that are accessed by said user for engaging an electrode to be utilized in performing said welding, wherein an artificial intelligence-based imaging unit 104 is installed at said distal end and integrated with a processor for capturing and processing multiple images in vicinity of said body 101, respectively to determine dimensions of said electrode positioned in vicinity of said distal end;
iii) a motor linked with each of said clamps 103 that are actuated by an inbuilt microcontroller to acquire a grip on said electrode while said user is performing welding using said electrode, wherein an inlet port 105 is integrated at said proximal end that is accessed by said user for connecting a conduit connected with an inert gas cylinder for supplying inert gas at said distal end via an electronically controlled nozzle 106 integrated at said distal end to aid said user in performing welding;
iv) an ultrasonic sensor 107 integrated at said distal end and synced with said imaging unit 104 for monitoring length of said electrode utilized in said welding, in accordance to which said microcontroller actuates multiple motorized rollers 108 integrated on an inner periphery of said clamps 103 to rotate for translating said electrode in a downward direction to aid in continuity of said welding process; and
v) an expandable plate 109 arranged at mid portion of said body 101 that is actuated by said microcontroller to get expanded for restricting flames or sparks generated from said welding process from reaching said user, wherein an air blower 110 is arranged at lower portion of said plate 109 that is actuated by said microcontroller to rotate for directing said sparks away from said user’s face.

2) The device as claimed in claim 1, wherein a glass shield 111 is assembled on upper portion of said plate 109 for allowing said user to visualize said welding process without any discomfort.

3) The device as claimed in claim 1, wherein a soft cushioned layer is fabricated on said handle 102 for providing comfortable experience to said user while holding said body 101.