Flexible Power Cable Optimization
Problem statement
Preventing muscle fatigue while welding is crucial for maintaining an efficient and productive workday, but holding up rigid, heavy power supply cables while welding all day can inhibit this. Miller Electric needs a lightweight and flexible welding cable to reduce operator fatigue while welding. The existing power cables cause a large moment about the welding torch, making it more difficult than necessary to maneuver the torch [1]. We intend to employ a parametric study on wall thickness and wire diameter to make the most flexible cable possible without altering materials to reduce the effort required to operate Miller welders. Ultimately, our solution will not only result in a lighter, more flexible power supply design for Miller, but also, a more ergonomically friendly welding cable option for all who use TIG welding.
[1] ‘Liquid-Cooled Cables | MillerWelds.’ Accessed: Sep. 29, 2023. [Online]. Available: https://www.millerwelds.com/products/induction-heating-systems/proheat-induction-heating-system/liquid-cooled-cables
Team members
Zach Karnz – leader
Matthew Novak – communicator
William Johnston – accountant
Michael Mehl – admin
Client
Michael Hoeger
Miller Electric Mfg. LLC