Welding wire feeder method

Abstract

A wire feeder device and method for feeding a welding wire includes a plurality of first and second gripper members movable from an open position to a closed position to engage on another and the welding wire along an engagement path. A projection from each gripping member is received in a recess defined in its engaged gripping member such that the welding wire is contacted on opposite sides in notches defined at the distal edges of respective projections. The gripper members may include a built-in centering function to center a position of the welding wire, may be made at least partially of material that conforms to the welding wire, and may be biased toward one another to firmly grip the welding wire.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application is a divisional application of, and claims priority from, U.S. patent application Ser. No. 15 / 668,014 filed Aug. 3, 2017 and entitled “Welding Wire Feeder Device”.FIELD OF THE DISCLOSURE[0002]Embodiments of the present disclosure relate generally to welding wire feeders and methods and, in particular, to a caterpillar style wire feeder and method.BACKGROUND OF THE DISCLOSURE[0003]Welding is a widely known process. Generally speaking, welding may be performed manually or, in some applications, it may be automated. Welding operations rely on a variety of types of equipment to ensure the supply of welding consumables (e.g., wire feed, shielding gas, etc.) is provided to the weld joint in an appropriate amount at the desired time. For example, a wire feeder is often used to provide welding wire at a desired feed rate to a welding torch.[0004]Wire feeders facilitate the feeding of welding wire from a wire spool or drum to a wel...

AI Technical Summary

Benefits of technology

The patent describes a welding apparatus that uses a roller chain with gripper members to position a welding wire properly for welding. The gripper members have projections with notches that contact the welding wire at different points along its length, minimizing potential distortion. The gripper members also have a centering feature to keep the welding wire parallel to its path. The roller chain is made of individual chain links, and the gripper members have a length that matches the length of a chain link to provide a larger contact area with the welding wire. The movement of the roller chain causes the gripper members to move between an open and closed position. The technical effect is a more precise and efficient welding process.

Problems solved by technology

In addition, the user often needs to change the rollers and wire guides when switching between welding wires of different diameters.

In addition to the time it takes to switch the rollers / guides, this also introduces the possibility that the user may use the wrong set of rollers and / or guides.

The user may also need to adjust the pressure of the feed rollers, which introduces the possibility that the user may incorrectly set the roller pressure, resulting in an undesirably high degree of wire deformation due to the high pressure.

In addition, the mechanism may become clogged as a result of a peeled wire caused by too much pressure and / or nonalignment in the mechanism, and unreliable feeding of the wire due to wire slippage (contact point friction).

Further, safety issues (e.g., finger pinching and the like) may be a concern as a user accesses and opens the mechanism.

Furthermore, prior art wire feeders that rely on a pair of rotating rollers generally require a high level of maintenance, which results in high maintenance costs associated with buying and stocking spare parts, and which increases the potential for improper maintenance practices.

Unfortunately, adding a second pair of rollers often creates new issues.

For example, with the introduction of a second pair of rollers, an increased risk exists for tangling of the wire, especially between the two pairs of rotating rollers.

Also there is an increased risk of “shaving,” which is the tearing-away of material from the surface of the wire due to misalignment between the grooves formed in the rotating rollers and associated nozzles, and due to slipping of the wire relative to the rotating rollers.

This can increase the possibility of clogging of the feed mechanism, the torch cable liner, and the torch.

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