Implementation system for continuous welding, method, and products for implementation of the system and/or method

Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns.

FIELD OF THE INVENTION

The subject invention relates to systems and/or methods of use for significantly increasing the amount of time between maintenance shutdowns in an automatic continuous welding application for an automated welding machine. Also disclosed are products which can be used to accomplish some of the steps of the processes or systems disclosed.

BACKGROUND

In the industry, various welding systems and processes are employed to weld two pieces of metallic material. For example, a diffusion nozzle (or nozzles in the case of twin electrodes) of a continuous electrode is moved near an article or articles to be welded, and an arc is established between the continuous electrode and the article or articles to be welded, so as to raise the temperature of the article or articles to be welded to the point at which the parts locally melt. Throughout the welding process an inert gas is dispensed through a gas diffuser disposed adjacent the nozzle to keep the molten metal at the weld engulfed in a controlled atmosphere. The controlled atmosphere controls the characteristics of the weld deposit as well as excluding air. Alternatively, a gasless wire tube may be used. The gasless wire tube contains chemicals which produce gas. The gases that cause the most difficulty in welding are atmospheric gases, particularly, hydrogen or H20. When any welding process is used, the molten puddle creating the weld should be shrouded or shielded from the air in order to obtain a high quality weld deposit. This can also help arc ignition and the transfer of electrode to pieces welded for a smoother weld.

A problem typically arises with this type of welding whereby spatter builds up on the front end of the torch, e.g., including a welding nozzle, tip and gas diffuser. Spatter is developed as molten metal droplets from the electrode and molten metal being welded are expelled and strike against the nozzle, tip and gas diffuser. The droplets of molten metal solidify and adhere to surfaces of the front end of the torch as deposits of spatter. When a significant amount of spatter accumulates on the surface of the nozzle, tip or gas diffuser adjacent the nozzle, the flow of inert gas to the weld is disturbed and becomes uneven.

Conventionally, spatter is removed by using a brush as disclosed in Japanese Patent Application Laying Open Publication Ser. No. 59-73186 (1984), or by using a device with rotary blades to scrape the spatter from the nozzle as disclosed in Japanese Utility Model Application Laying Open Publication Ser. No. 58-47381 (1983). However, the usefulness of these methods is limited as direct contact with the welding nozzle is likely to cause damage to the welding nozzle, and the brushing or scraping of the welding nozzle is extremely time and labor intensive. Another approach involves the use of ceramic welding nozzles, instead of metal welding nozzles, as disclosed in Japanese Utility Model Application Laying Open Publication Ser. No. 48-12323 (1973). However, even though the use of ceramic material reduces the amount of spatter accumulation, spatter removal must still be performed, and a ceramic welding nozzle is even more susceptible to damage when the spatter is removed by scraping or brushing. In all of these cases it is necessary for the operator to be in close proximity to the welding nozzle in order to remove the spatter, which may lead to injuries, such as when an operator is burned by the extremely hot welding nozzle while trying to clean it by hand.

In order to make the process more streamlined, and to reduce the danger to the operator, spatter may be removed from the welding nozzle by inserting the welding nozzle within an electromagnetic field that magnetically pulls the spatter accumulation from the welding nozzle. A product performing this function is disclosed in U.S. Pat. No. 4,838,287. This product allows the spatter accumulation to be removed with no physical contact to the welding nozzle and with no requirement for the operator to get close enough to the welding nozzle to be burned. This product also can be utilized with an automated welding system application such that the electromagnetic cleaner is placed within reach of an automated welding system, where periodically the automated welding system would automatically move the welding nozzle over to the cleaning station to have the spatter accumulation removed. The product allows the automated welding system to clean the nozzle and continue operation without being shut down. Since the welding nozzle is cleaned often, the life of the welding nozzle is also increased so that it need not be replaced as often as it would without the cleaning procedure.

However, this product does not work well with a metal welding nozzle because the spatter bonds very strongly to the metal welding nozzle. Typically this product will only be used effectively with a welding nozzle made from either a ceramic or a carbon composite material. Characteristics of carbon composite or ceramic materials make welding nozzles made therefrom resistant to adhesion and to pitting. The resistance to adhesion allows the use of the electromagnetic cleaner to efficiently remove spatter from the various elements of the ceramic or carbon composite welding nozzles.

In process, the ceramic or carbon composite welding nozzle may be dipped in water prior to cleaning in order to solidify the spatter. The electromagnetic field will not be effective if the spatter is in a liquid or molten state, so the water dip is necessary to insure that the spatter is completely hardened. After dipping the welding nozzle in water, the welding nozzle is moved to the electromagnetic station and the hardened spatter droplets are pulled off magnetically.

Another measure utilized to prevent spatter accumulation or to at least make spatter removal easier are anti-spatter compounds. These compounds can be liquid, gel, or an aerosol spray. When placed on the welding nozzle, the anti-spatter agent will act as a barrier between the molten droplets of metal and the welding nozzle to either prevent or weaken the bond to the welding nozzle after the molten metal droplets cool. Use of an anti-spatter compound generally slows the accumulation of spatter on the welding nozzle and makes for the easier removal of any spatter that accumulates on the welding nozzle. However, the usefulness of the anti-spatter compounds is limited in that unless applied before each weld, the anti-spatter compound will be consumed with successive welds, thereby requiring frequent shutdowns of the welding operation to manually apply fresh anti-spatter compound to the welding nozzle. Each stop makes the cycle time longer, and also requires an operator to manually apply the anti-spatter compound. Generally, the use of anti-spatter compounds in this manner has had minimal beneficial effects due to the labor-intensive nature of the application in any manufacturing setting.

Welding contact tip is another significant cause of downtime on a welding operation. As a contact tip is used, it wears out due to arcing and abrasion. Friction and/or conductivity between the continuous electrode and the passage for the electrode in the contact tip causes the passage in the welding nozzle to become out of round and enlarged, which, in turn, permits the continuous electrode to move around in an uncontrolled manner within the passage. Such action eventually causes inaccuracy in the weld and eventually requires that the contact tip be replaced. To prevent or postpone this wear on the contact tip, feeders have been developed to feed the continuous electrode to the contact tip in a defined manner, because some contact between the electrode and the contact tip has been found to bear on the repeatable accuracy of the weld. Lubricants can also be applied to the continuous electrode to reduce the function between the continuous electrode and the contact tip.

SUMMARY OF THE INVENTION AND ADVANTAGES

Various methods and/or systems are disclosed for providing an improved welding system and/or method that substantially improves the length of time of continuous operation for an automated welding system between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a welding nozzle or tip and a portion of its related diffuser into a bath of fluid each time the automated welding system moves through a welding cycle. A product that may best accomplish this step or element is also disclosed.

Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the nozzle or diffuser. A further disclosed method step or system element includes lubrication of the continuous electrode used for welding, and may include a step prior to lubrication that involves cleaning the continuous electrode prior to adding lubricant. The steps may vary as to whether or not they are included, or in what sequence, in accordance with such factors as the type of material used for the tip, the feeder used, the type of continuous electrode used, the type of spatter removal system to be used, the welding apparatus used, the welding environment (such as the inert gases used), and the welding application, i.e., what material is being welded to what material, and other factors. In each system or combination of method steps disclosed, however, a significant increase in time of continuous operation between maintenance shutdowns has occurred, providing significant cost savings and higher productivity for the same machine. Products for implementing the systems and/or methods are also disclosed, as well as a product that will hold or combine various products as needed for a selected system and/or method.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the FIGS., wherein like numerals indicate like or corresponding parts throughout the several views, with particular reference toFIG. 5a, an apparatus10for providing a bath12of a fluid to an automated welding system14is shown at10. The apparatus10includes a port16for the adaptation of a feed container17of fluid18, a reservoir20which is accessible to atmosphere, and a passageway22for communication between said feed container18and said reservoir20. The port16is preferably comprised of a connection between a threaded spout15to the feed container17containing the fluid18and a mated threaded inlet19to the passageway22. The apparatus10further provides means for maintaining the fluid bath12at a constant level within the reservoir20until the feed container18is exhausted. The relationship between the reservoir20and the feed container18is such that the apparatus10provides a balance between the surface tension of the fluid within the reservoir20and in contact with the atmosphere against the head created by the feed container18in communication with said passageway22. This relationship allows the level of the fluid bath12within the reservoir20to be maintained at a constant level as long as additional fluid remains within the feed container18. As the fluid bath12within the reservoir20is used, the volume of the fluid bath12within the reservoir20is replenished via the passageway22between the reservoir20and the feed container18. Additionally, a level sensor11may be used to detect a low level within the fluid bath12. If a low level is detected, then the welding system14may be shut down.

With reference toFIG. 3, an example method of using the apparatus10to increase the duty cycle of an automated welding system14is shown. The automated welding system14includes a torch25.

In one embodiment, the torch25includes a front end26. The front end26includes a nozzle30, a gas diffuser32, and a contact tip34. The torch26is connected to a robot36. A conduit31is also coupled to the torch25for supplying material to the torch25, e.g., gas, water, and a continuous electrode (see below).

The method includes the steps of using a continuous electrode feeder device24to feed the continuous electrode26to and through the contact tip34, applying a friction reducing agent to the continuous electrode26as it is fed by said feeder device24to said contact tip34, dipping said front end28into a fluid bath12contained within said reservoir portion20of said apparatus10following a welding cycle, and utilizing a spatter removal device, such as an electromagnetic spatter removal system54, to remove spatter from said front end28. The continuous electrode feed mechanism24is used to insure that the continuous electrode26is consistently and smoothly feed to the contact tip34, and the friction reducing agent is applied to increase the feedability of continuous electrode26into and through the contact tip34. The friction reducing agent is preferably applied by means of a continuous electrode lubricator50having an applicator70fed via a wicking action from a reservoir72, which can be disposed in a housing76, having a inlet passageway78and an outlet passageway80. The housing76is preferably disposed between the feeder24and the supply container82(or source) for the continuous electrode26. A cleaner may also be applied to the continuous electrode26utilizing a similar device (not shown) located adjacent the continuous electrode lubricator50.

As discussed above, in one embodiment, each torch25has a front end28which may be comprised of a nozzle30, a gas diffuser32, and a contact tip34. Alternatively, the front end28could include a flux core wire continuous electrode, a gasless wire tube and/or a nozzle. The flux core wire continuous electrode includes chemicals that produce the gas.

The torch25is mounted to the robot arm36in a conventional manner. The gas diffuser32is connected to a source of preferable inert gas. Holes33in the gas diffuser32distribute the gas into the welding nozzle shroud30to control the welding environment at the weld.

With reference toFIG. 6acontact between the contact tip34and the continuous electrode26is desirable for stability and repeatability of electrode feed, but will cause the feed hole35in the contact tip34to become out of round or enlarged at some point, thereby requiring more frequent replacement of the contact tip34, if high abrasiveness and arcing exist. Use of the friction reducing agent on the continuous electrode26will help maintain conductivity between the continuous electrode26and the contact tip34, which increases the life of the contact tip34for repeatable welding of the parts to be welded.

For metal welding nozzles, the fluid bath12consists of a release agent, a solution of water and a release agent, or water. The release agent is used to prevent liquefied spatter that is deposited on the front end28of the torch25from forming a strong bond. Additionally, by quenching the front end28of the torch25in the fluid bath12between welding cycles, the front end28is repeatedly heated and cooled. The unequal rates of expansion and contraction of the spatter and the components of the front end28also work to remove the spatter from the front end28. The fluid bath12including the release agent is kept at a cool temperature in order to facilitate the hardening of the liquefied spatter. The temperature of the fluid bath12is dependent on the amount of time which the front end28of the torch25is immersed within the release agent. The temperature of the fluid bath12including the release agent must be cool enough to cause the liquid spatter to completely harden within the amount of time that front end28of the torch25is immersed. Typically, a release agent must be used when a welding nozzle30composed of metal is utilized due to the high strength bonding which occurs between the spatter and the metal nozzle30. The release agent is necessary to insure that the bonding between the front end28and the spatter is inhibited sufficiently to allow the spatter to be removed without damaging the front end30.

Typically, as shown inFIG. 5a, the front end28is dipped into the fluid bath12so that the surface13of the fluid bath12is disposed adjacent the holes33of the gas diffuser32, e.g., ¼ inch, so that no fluid enters the inside of the gas diffuser32via the diffusion holes33at any time.

After the front end28has been dipped within the fluid bath12including the release agent, the front end28is then removed from the fluid bath12and positioned at its next station above a spatter removal system54. In one embodiment, the spatter removal system54is an electromagnetic spatter removal system54. The spatter must be completely hardened in order for the electromagnetic spatter removal system54to work correctly. The electromagnetic spatter removal system54uses magnetic fields to attract the spatter and pull the spatter from the front end28, such as that described above and shown in U.S. Pat. No. 4,838,287. This process step or system element will not work on spatter that is still liquefied. In one embodiment, the steps or elements of dipping the front end28within the fluid bath12including the release agent and subsequently utilizing the electromagnetic spatter removal device54are performed periodically each time the automated welding system 14 cycles a predetermined number of times.

A different example method or system of using the fluid bath apparatus10to increase the duty cycle (i.e., on duty, between shutdowns) of an automated welding system14includes the steps or elements of using a continuous electrode feed mechanism24to feed the continuous electrode26to a contact tip34of a front end28aof a torch25, applying a friction reducing agent to the continuous electrode26as it is fed through the feed device24to the contact tip34, dipping the front end28ainto a fluid bath12contained within said reservoir portion20of said apparatus10following a welding cycle (preferably where the surface of the fluid bath is disposed approximately ¼ inch from the holes33of the gas diffuser32), and utilizing an electromagnetic spatter removal system54to remove spatter from said front end28a. In place of the metal nozzle30, however, a ceramic nozzle30ais utilized. A ceramic welding nozzle30ais more resistant to bonding of the spatter, thereby making the spatter removal easier. The inherent resistance to bonding displayed by the ceramic welding nozzle30amakes the use of a release agent in the fluid bath12unnecessary. Therefore, instead of dipping the front end28ainto a fluid bath12of water and a release agent, the front end28ais dipped into a fluid bath12aconsisting of only water. Just as with the release agent, the water only fluid bath12amust be kept at a temperature which will allow the spatter to completely harden upon the front end28aprior to utilizing the electromagnetic spatter removal system54.

An additional example method of using the fluid bath apparatus10to increase the duty cycle of an automated welding system14includes only using the steps or elements of using a continuous electrode26feed mechanism to feed the continuous electrode26to a contact tip34, dipping said front end28into a fluid bath12contained within the fluid bath12of said fluid bath apparatus10following a welding cycle, and utilizing an electromagnetic spatter removal system54to remove spatter from said front end28. As previously discussed, the method can be practiced using a front end28ahaving a nozzle30amade from ceramic materials rather than metal and dipping the front end28awithin a fluid bath12aof only water rather than a release agent to harden the spatter deposited on the welding tip28a. Alternatively, if a metal nozzle30is used, a release agent plus water is recommended.

An additional example method of using the fluid bath apparatus10to increase the duty cycle of an automated welding system14includes the steps of using a continuous electrode feed mechanism24to feed the continuous electrode26to a contact tip34, dipping said front end28into a fluid bath12of said apparatus10following a welding cycle, and using a scraper or brush to remove the hardened spatter from the front end28. An impact device or a reamer may be other alternatives to remove the hardened spatter from the front end28. As previously discussed, the method or system can be practiced using a metal welding nozzle30and a fluid bath12including a release agent (or a solution of a release agent and water), or a ceramic welding nozzle30aand a water fluid bath12ato harden the spatter deposited on the welding nozzle30or30a, respectively. Although the electromagnetic spatter removal system54is not utilized in the present method, the release agent or water must still be maintained at a temperature which will facilitate the complete hardening of the spatter deposited on the welding nozzle30or30a, respectively. Removal of the spatter by scraping, brushing, reaming, or impacting does involve some manual labor, but the removal process has been found to be more efficient than those previously known, particularly when the spatter is completely hardened by the dipping of the front end28or28ain the fluid bath12or12a, respectively. The steps or elements of dipping the front end28or28awithin the fluid bath12or12aand subsequently removing the hardened spatter by brushing, scraping, reaming, or impacting the hardened spatter from the front end28or28aare performed periodically at shutdown subsequent to each time the automated welding system 14 cycles a predetermined number of times. This method will improve the amount of time between shutdowns, but is not recommended to be as significant as the other methods and/or systems described above.

Referring toFIGS. 1 and 2, an automated welding system utilizing the fluid bath apparatus10is shown at14. Referring toFIG. 3, a schematic-is shown which details the path of the continuous electrode26as it is fed from a spool through a continuous electrode lubricator50to the contact tip34,FIGS. 3 and 4illustrate the mounting of the fluid bath apparatus10via bolt fasteners or similar fasteners onto a bracket100along with the electromagnetic spatter removal system54, similarly mounted with bolt fasteners or similar fasteners. As shown inFIG. 4, this bracket100is then affixed to a stand102via suitable fasteners (or may be fastened by welding or any other desired type of fastening that will retain its fastening in the environment in which the robot is maintained). The stand102is placed in a suitable location, as shown inFIG. 4, to be reached by the robot arm36for placement of the front end28or28aat an appropriate time in the cycle.

With reference toFIGS. 1 and 2, the stand102is preferably placed within the automated welding system14, but away from the area108in which welding is performed. For example in the illustrated embodiment, the stand102is disposed at a location approximately 90 degrees clockwise from the working area108as viewed from above. At should be noted that 90 the location of the stand102is dependent upon the application and may be placed at a location other then 90 degrees from the working area108. The fluid bath apparatus10and the electromagnetic spatter removal system54are placed in sequence on the stand102so that one is less than 90 degrees clockwise from the work area108as viewed from above and the other is more than 90 degrees clockwise from the work area108as viewed from above, so that the operation steps or elements can be sequential, if so desired.

Returning toFIG. 4, in one embodiment, the bath12includes a bleeder apparatus84coupled to the reservoir20. The bleeder apparatus84includes a bleeder line86coupled to the reservoir20by a coupler88at one end and to an overflow container90. The bleeder apparatus84is adapted to catch any overflow from the reservoir20to maintain fluid level within the reservoir20at the fill line13a. The overflow is held in the overflow container90and may be emptied into the fluid container17.

Referring toFIG. 7, a flow chart is shown which illustrates the possible methods or systems of use as described above. As shown, the flow chart begins with a continuous electrode feed mechanism24that may be used to feed the continuous electrode26from a spool to the contact tip34. A continuous electrode lubricator50may be located immediately after the spool to apply lubricant to the continuous electrode26. The lubricant will reduce friction as the continuous electrode26is fed to the contact tip34, and will reduce friction between the contact tip34and the continuous electrode26as the continuous electrode26passes through the contact tip34. Reduced friction and increased conductivity between the contact tip34and the continuous electrode26will reduce the amount of wear on the contact tip34, thereby increasing the life of the contact tip34. As shown inFIG. 7, the use of a continuous electrode lubricator50is optional, although it is preferable, but the method can be practiced without the continuous electrode lubricator50at an improved efficiency, but less than the efficiency with the use of the lubricator50.

The welding nozzle30,30acan be made of either metal or ceramic material. If the welding nozzle30is made from metal, then the welding nozzle30is preferably dipped within a fluid bath12consisting of a release agent or a solution of water and a release agent. The release agent is used to prevent liquefied spatter that is deposited on the front end28from forming a strong bond to the surfaces of the front end28, and is kept at a cool temperature in order to facilitate the hardening of the liquefied spatter as described above.

If the welding nozzle30ais made from a non-metal material, then the welding nozzle30ais dipped within a fluid bath12aof only water if it is a carbon nozzle. If the nozzle30ais a ceramic nozzle, it need not be dipped other than if the spatter needs to be cooled, in which case some improvement over other uses of ceramic nozzles can be maintained. Thus, with ceramic nozzles this step is optional. The inherent resistance to bonding displayed by the carbon or ceramic welding nozzle30amakes the use of a release agent less effective. Therefore, instead of dipping the front end28into a fluid bath12of water and a release agent, the front end28ais dipped into a fluid bath12aconsisting of only water. Just as with the fluid bath12including the release agent, the fluid bath12aof water must be kept at a temperature which will allow the spatter to completely harden upon the welding tip28a. The fluid bath apparatus10is used to present the fluid bath12ato the front end28ain a manner that the front end28acan be dipped within the solution as described above.

After the front end28or28ahas been dipped within the fluid bath12or12a(or otherwise as indicated inFIG. 7as to ceramic nozzles), then the front end28or28ais positioned so that any spatter which has accumulated upon the front end28or28acan be removed by either an electromagnetic spatter removal system54, by brushing, reaming, scraping, or impacting (such as with a hammer), using ultrasonic, or other force, the spatter from the front end28or28a. The electromagnetic spatter removal system54uses magnetic fields to attract the spatter and pull the spatter from the front end28or28a. If the electromagnetic spatter removal system54is not used, then any spatter that has accumulated upon the front end28or28acan be removed manually by either scraping, brushing, reaming or otherwise impacting the spatter from the front end28or28a. The steps of dipping the front end28or28awithin the release agent or water and subsequently utilizing the electromagnetic spatter removal device54or scraping, reaming, brushing or otherwise impacting the spatter from the front end28or28aare performed periodically each time the automated welding system 14 cycles a predetermined number of times.

With reference toFIGS. 8aand8b, in one aspect of the present invention, the bath12includes a cooling system42. Heat from the front end28or28ais transferred to the fluid18within the bath12. The cooling device42helps to eliminate heat from fluid18within the bath12. Thus, the bath12may be smaller relative to the front end28or28a.

With specific reference toFIG. 8a, in one embodiment, the cooling system42includes a solid state cooling element44, such as a Peltier Device, within the reservoir20. A Peltier Device is a solid state thermoelectric module which acts as a heat pump.

With specific reference toFIG. 8b, in another embodiment, the cooling system42includes an element46wrapped around or in contact with at least a portion of the reservoir20. The element46may be cooled with a refrigerant, such as freon or liquid nitrogen or other cooled liquid. The element46includes one or more tubes or passageways48through which the refrigerant flows. The element46may be outside the reservoir20, as shown, or inside the reservoir20. Apparatus for cooling refrigerants and flowing the refrigerant through tubes are well known in the art and are therefore not further discussed.

With reference toFIGS. 9a,9b, and9c, in another aspect of the present invention, the electromagnetic spatter removal system54includes a magnetic device52disposed within the fluid18in the reservoir20. In one embodiment, the magnetic device51is a magnet disposed within the bath torch12. In another embodiment, the magnetic device52is an electromagnetic coil device adapted to be energized by the electromagnetic spatter removal system54when the front end28or28ais inserted into the bath12. Energization of the electromagnetic coil device52creates a magnetic field. The magnetic field created by energization of the electromagnetic coil or the magnetic field created by the magnet operates to remove spatter from the front end28or28a.

A wire basket or net56is adapted to be inserted into the bath12to catch or contain the spatter removed from the front end28or28a. The basket56, in one embodiment, is composed of stainless steel. In an alternate embodiment, the basket56is composed of plastic. The basket56is designed to catch the spatter removed from the nozzle28by the electromagnetic spatter removal system54. The basket56includes a handle58by which the basket56may be removed from the reservoir20and emptied. The basket56also includes a lip58awhich rests along the top edge of the reservoir20. The basket56may be rigid or collapsible.

In the illustrated embodiment, the electromagnetic coil device52includes a coil52awrapped about a base52b. A pair of leads60connects the coil52ato a charging circuit62of the electromagnetic spatter removal system54. The base52bis connected to a support structure64which supports the electromagnetic coil device52such that the device52in below the fill line13aof the reservoir20. The support structure64includes a plurality of arms64awhich extend away and in a direction up (inFIG. 9b) from the base52b. The arms64aare adapted to rest on top of the basket56and thereby removable position the electromagnetic coil device52within the reservoir20.

In one embodiment, the coil52aand the leads52care electrically insulated, e.g., coated or sheathed in insulating plastic or rubber. In another embodiment the fluid18within the reservoir20is non-conducting.

In operation, when the front end28or28ais inserted into the bath12, the electromagnetic spatter removal system54energizes the coil52avia the charging circuit, thereby, creating a magnetic field which acts to remove spatter from the front end28or28a. The spatter is contained within the basket56and can thereafter be removed from the bath12.

With reference toFIGS. 10a,10b, and10c, in another embodiment the bath12includes a brush66within the reservoir20. The brush66may be composed of stainless steel. The brush66is positioned such that the front end28or28ais inserted into the brush66when inserted into the reservoir20. The brush66is used to remove spatter from the front end28or28awhen the front end28or28ais inserted therein. The brush66includes a plurality of bristles66a. In one embodiment, as shown inFIG. 10b, the bristles66aare in a circular pattern. In another embodiment, as shown inFIG. 10c, the bristles66aare in a donut shaped pattern. The donut shaped pattern corresponds to the shape and dimensions of the nozzle28.

Returning toFIG. 10a, in one embodiment the brush66is coupled to the bottom of the reservoir20via a bracket66b. In another embodiment, the brush66is coupled to the bottom of the basket56. As above, the basket56may be removed to remove the spatter from the reservoir20. The brush66and basket56combination may be used with or without the electromagnetic coil device52ofFIGS. 9a-9c. If the brush66is used with the electromagnetic coil device52, the brush66may be connected either the basket56or the base52or support structure66(see FIG.11).

With reference toFIG. 8c, in another aspect of the present invention, a torch chiller or cooler110may be utilized to cool the front end28of the torch25to remove spatter from the front end28. The torch cooler110may be use used independently or in combination with the other spatter removal devices. In one embodiment of the present invention, the torch cooler110contains a cooling material112which may be in the form of a fluid (liquid or gas) or solid. Examples of liquids that may be suitable include, but are not limited to, oil, a mixture of oil and water, anti-freeze solutions (such as those containing ethylene glycol and propylene glycol), and/or any suitable fluid which may be used to cool the torch. Suitable gases include inert gases such as nitrogen gas. Cooling material112in the form of solids may be in pellet form and may include dry ice or other suitable material.

The cooling material112is within a container114which has an aperture116for insertion/removal of the front end28of the torch25. The container114may also include a closeable second aperture118. A filter or screen122may be placed within the second aperture120. A flush device122may be coupled to the container114at the second aperture120. The flush device122includes a valve (not shown) for opening and closing the second aperture120and releasing the material from the container114.

The torch cooler110may also include a cooling element124, such as a Peltier Device. The cooling element124is used to cool the cooling material112. Alternatively, if the material112is a fluid, the cooling element124may remove the fluid from the container114, cool it, and pump it back to the container114.

In still another aspect of the present invention, the fluid bath12includes a torch cleaner. The nozzle30,30A, of the welding torch25may be made of various materials, such as a ceramic, copper, brass, or chrome. A suitable cleaner for the nozzle30,30A is chosen. The cleaner in the fluid bath12acts to clean the nozzle30,30A from its end up until the point at which it is dipped into the fluid bath12. This allows a visual indication of how far the nozzle30,30A is being dipped into the fluid bath12. As a visual indication, a person does not need to enter the work area, and thus, requiring that work being performed by halted, to confirm that the nozzle30,30A is being dipped into the fluid bath12.