Device for applying torsion to a wire

Abstract

The present invention provides a device for applying torsion to a wire, the device having a base and a support member mounted to be rotatable relative to the base about a rotation axis. The rotation axis is aligned with a wire path extending through the base and the support member. Further, a wire clutch device is mounted on the support member and adapted to engage at a wire guided along the wire path, and a rotation mechanism is provided which is adapted to rotate the support member relative to the base.

Description

Technical Field

[0001] The present invention relates to a device for applying torsion to a wire, which may be a welding wire. Background Art

[0002] Wire consumables are used in many industrial applications: from surface treatments such as metallization to the joining of metal components in welding. In the coming years, wires will be increasingly utilized in the very important and continuously improving field of 3D printers.

[0003] In many industrial applications where significant investments have now been made in automation and robotic systems, it is crucial to achieve maximum productivity, and large-volume containers with a large number of consumables are superior to smaller spools because large-volume containers allow for reduced interruptions and minimal spool change downtime. Parameters generally accepted in the welding industry for measuring changeover downtime indicate that it typically takes an average of 15 minutes to replace an empty 15-kilogram spool with a brand-new one, and spool change downtime can thus be quantified as one minute for every kilogram of wire converted. According to this calculation, it is clear that a large package or drum containing 1200 kilograms of product is equivalent to saving 20 hours of changeover downtime. These 20 hours can be better utilized for active production rather than continuously interrupting production due to spool changes: this advantage can translate into a significant reduction in production costs and an improvement in the efficiency of the manufacturing process.

[0004] It must be added that every unwanted production stoppage can lead to additional complexities and drawbacks in terms of quality consistency because in some welding processes, such as the production of fuel tanks or long welds on trailers or railway vehicles, it is generally unacceptable to stop in the middle of the weld, but rather it is preferred to be uninterrupted from the start to the end of the welding process; in some metallization or welding applications, unwanted intermediate interruptions can lead to the complete rejection and scrapping of the component.

[0005] Now, through the wire feeding systems available on the market, packages containing a large number of wire consumables can be centralized in a specific centralized area (referred to as the "wire yard") that is at a safe distance from the dangerous sparks generated by the welding arc and is convenient for forklift handling, where the wire feeding system can help convey the wire smoothly and frictionlessly from the packaging location to the welding or metallization torch where the wire consumable is actually melted or fused through a conduit that can reach a distance of 100 meters. Being able to place large packages in a safe centralized area, in addition to reducing the risks associated with handling and conveying and the danger of welding spark ignition, also makes inspections easier without having to enter the perimeter of the production unit and ultimately negatively impact the production cycle.

[0006] Large-volume packages that allow continuous production without interruption and contain large amounts of wire rod represent the basic requirement for a wire rod yard setup with high productivity.

[0007] The support members for the wire rod have different forms: from small spools that carry only 0.5 kg of product to large-volume containers that carry up to 2 tons of product.

[0008] There are various methods for storing large amounts of wire rod consumables on or inside large-volume containers: from large spools that require some rotary unwinding equipment to reel winches that must be placed on a turntable to empty their contents. However, in both cases, the wire rod is exposed to possible contamination, which can lead to rusting and welding porosity, and any rotary equipment used to unwind large wire rod spools or reels occupies valuable and sometimes urgently needed floor space.

[0009] A few years ago, a third and definitely more efficient system was developed: a winding machine that applies a counter-torque to plastically deform the wire rod by straightening, stretching, and rotating the wire rod and then lays the wire rod into a container in the shape of a horizontal coil. When the wire rod is released for consumption, the wire rod can be easily and smoothly withdrawn from its fixed container without any major feeding difficulties and without a turntable or unwinding device, and if the winding process is correctly completed, the wire rod will not tangle before leaving the package. This process is called "untwisted" winding, but this is not easy to do, and sometimes, depending on the hardness, column strength, grade, and chemical properties, the wire rod will still maintain a certain tension, which must be controlled by a retainer plate that changes in weight and shape during withdrawal, where the retainer plate is usually placed on the wire rod coil to ensure that only one strand is withdrawn from the container at a time. If more loops are accidentally fed out during withdrawal, the direct consequence will be tangling and production interruption.

[0010] The prior art teaches many inventions that focus on developing or improving various systems for holding and braking the wire rod during payoff: from plates of various shapes to spherical marbles that freely fall on the wire rod or a holding device with a rotary wire rod guiding arm and ribs under the plate to ensure that only one strand is pulled out and no more loops are pulled out simultaneously; the problem is that if the tension on the wire rod released from the package is too high, some wire rod loops will inevitably be dragged towards the central plate opening, and if the wire rod moves during conveyance, the wire rod may fall and tangle at the plate opening regardless of the type of retainer used. The first reaction is often to increase the holding weight to keep the wire rod restricted, but if the retainer plate is too heavy, the retainer plate will inevitably deform the wire rod, and the deformed wire rod will cause problems with arc drift and thus welding quality problems, and even very heavy retainers cannot always keep the wire rod under control.

[0011] In many prior art patents, various wire holding systems for aluminum wire and all steel wire are generally described:

[0012] US 5,746,380 describes a layer of spherical elements on a wire coil to control wire payout.

[0013] WO 2016 / 022389 presents a combination of a retaining plate with ribs and a wire guiding rotating arm, where the rotating arm has the ability to hold the wire constrained and limit the movement range of the wire while guiding the wire outward.

[0014] US 7,410,111 teaches a retaining plate with openings to be lighter and prevent deformation of aluminum wire.

[0015] US 7,950,523 describes a combination of two plates that interact to control wire strands so that the wire strands are not mispositioned during conveyance and handling.

[0016] All previously proposed solutions can fail in the case of the wire being overloaded with tension, because ways can be found for the wire to slip uncontrolled under the retaining plate and fall into the central part of the package where the final wire entanglement occurs.

[0017] The equipment efficiency combined with the skills of the operator and a reliable wire retaining plate can truly achieve minimizing the residual tension left on the wire during untwisted winding and ensuring smooth wire feeding. However, some other variable factors may intervene during wire extraction and have a negative impact on wire performance: improper adjustment of the pressure roller of the wire feeder or wear of the guiding groove of the pressure roller or a "U" - shaped instead of a "V" - shaped guiding groove and a "V" - shaped instead of a "U" - shaped guiding groove, or even worse, an incorrectly sized groove that does not match the diameter of the wire used. All of the above can cause tension to be applied to the untwisted winding wire when it is pulled out of its container, and once the tension accumulates beyond the braking effect exerted by the retaining plate, the wire will pop out unrestricted and ultimately become entangled and get stuck inside the package in the form of a single knot or an uncontrolled mass of loops, resulting in production interruption, which is something to be avoided first when designing large - volume packages.

[0018] The problem of residual tension remaining on the wire after untwisted winding seems to be more severe for 5000 - grade aluminum wire, but this affects all aluminum wires and the harder steel wires that are more difficult to deform. The properties of 5000 - grade aluminum wire are very unpredictable and may be related to the chemical properties of the wire itself or the hardness of the wire, which may vary depending on the annealing treatment the wire has undergone during production. It has been noted that 5000 - grade aluminum welding wire has a tendency to partially return to its pre - twisted state after being kept stored in its bulk packaging for a given period of time, and the smaller the container diameter, the more severe this "static" deformation seems to be.

[0019] In summary, even after the untwisting winder has correctly laid the untwisted wire in the packaging, other negative variable factors (equipment defects, incorrect adjustments, adjustments to the container shape, etc.) can still have a negative impact on the wire properties, even if the operator uses skill and special considerations when adjusting the winder.

[0020] The scope of the present invention is to intervene in the wire at some positions between the wire coil and the wire feeder by canceling and neutralizing the residual tension of the wire to such an extent that it may not even be necessary to use a pay - off control retainer plate or at least a very light and flexible retainer plate can be used instead. Summary of the Invention

[0021] The present invention is designed to ensure smooth and trouble - free wire pay - off from bulk packaging, especially for aluminum welding wire, but the present invention generally applies to all wires after being placed in bulk packaging through untwisted winding treatment.

[0022] Generally speaking, the present invention includes anti - tension rotating means that can be positioned at any position between the wire coil and the wire feeder. In a preferred embodiment, and to maximize its effectiveness, the device is installed on top of the dome, exactly at the position where the wire exits the packaging.

[0023] The device is equipped with at least one, but preferably two (or more) wheels, the guide grooves of which lock onto the wire, and the wheels impart an anti - twist motion to the wire by rotating the wire around its axis in a given direction (clockwise or counter - clockwise), preferably the unwinding direction of the wire itself. This anti - twist will cancel any tension still present on the wire, whether due to incorrect untwisted winding treatment or excessive tension accumulated on the wire due to poor wheel pressure adjustment or damage / wear of the feeder roller grooves.

[0024] In addition, the anti - torsion force applied to the wire conveniently keeps the wire pushed towards the outer edge of the wire coil, thus preventing the wire loop from uncontrollably falling into the open free space at the central part of the bulk packaging, even after the wire has been accidentally displaced during handling or transportation.

[0025] The rotation of the tension release device can be enabled in two ways:

[0026] (1) By the mechanical combined action of two or more wheels that are connected to the rotating pad base and interact with the rotating pad base through bevel gear devices. For such an embodiment, a group of one or more grooved wheels (preferably two) are pushed against the wire being pulled by the feeder, and then, due to their bevel gear devices, the wheels in turn engage the toothed pad base and rotate the base: in rotation, the wheels "clutch" or grip the wire and apply a counter-twist force to the wire in a predetermined desired direction, where the rotational speed and direction of rotation depend on the shape and orientation of the bevel gear devices.

[0027] (2) By an electric motor that automatically determines the direction of twist along the wire axis when the wire is being paid out. In this case, the motor speed and the rotation of the wire are controlled by an external PLC, which can be embedded in the wire feeder (as in the preferred embodiment) or located outside the wire feeder.

[0028] In the mechanical embodiment, the tension release rotational speed cannot be adjusted or paused later, while the motor-operated tension release device (which can be of any known type, such as DC, AC, brushless or stepper) is definitely preferred and more flexible because it can be programmed by the PLC to automatically perform multiple important functions. The direction of rotation applied to the wire can be adapted to the winding direction of the wire. In addition, the controller can determine when excessive counter-tension has accumulated on the wire and thus enable or pause the rotation of the pad and the grooved wheels as needed by an electromagnet that engages or disengages the motor.

[0029] The engagement of the motor can also be enabled by a pneumatic or magnetic piston that pushes the moving part of the device carrying the motor against the rotating pad carrying the group of grooved wheels, which helps to apply a counter-twist action to the fed wire. Although in this case the motor rotates continuously and the motor only engages the rotating pad when it is necessary to apply a counter-twist to counteract the accumulated tension on the wire, the motor can also continuously engage the rotating pad through a belt or bevel gear device, and in this case, the function of the motor must be controlled and programmed by an external PLC.

[0030] Generally speaking, even without using a retainer plate, the cancellation of the tension generated by the counter-twist of the wire along its axis in the clockwise or counterclockwise direction as needed can actively promote smooth wire payout; or, if a retainer plate is preferably used, the retainer plate can at least be very light and flexible, and this is definitely beneficial for preventing possible deformation of softer aluminum wires.

[0031] In a preferred embodiment, the retainer plate can still be placed on the wire coil and bonded to the wire during handling and conveyance, but for easy removal, the retainer plate can be easily divided into two or more parts even after the wire has been inserted into the guide catheter.

[0032] The present invention provides an apparatus for applying torque to a wire, the apparatus having a base, a support member, a wire engaging device, and a rotation mechanism. The support member is mounted to be rotatable relative to the base about a rotation axis that is aligned with a wire path extending through the base and the support member. The wire engaging device is mounted on the support member and is adapted to engage the wire being guided along the wire path. The rotation mechanism is adapted to rotate the support member relative to the base. The wire engaging device mechanically engages the wire such that the wire engaging device can apply torque to the wire to a desired degree.

[0033] The wire engaging device can be implemented in any form that allows the wire to pay out (meaning: translational movement of the wire along the wire path) and simultaneously apply a rotational movement to the wire. Preferably, the wire engaging device is a pair of rollers mounted on the support member, the rollers being arranged on opposite sides of the wire path, and at least one of the rollers having a wire receiving groove. A pair of rollers is a very simple but effective means for mechanically engaging the wire at the wire to rotate the wire about the axis of the wire and simultaneously allow the wire to pay out.

[0034] To ensure that different wires can be reliably rotated about their axes, a biasing device is provided for biasing the two rollers against each other so that the engaging force can be adapted to specific requirements.

[0035] The biasing device can include a handwheel for applying a tightening torque to the biasing mechanism, and a torque limiter is provided in the torque path from the handwheel to the biasing mechanism. The torque limiter prevents the biasing device from applying an excessive force to the wire.

[0036] According to one embodiment, a spring-loaded cam mechanism is provided that connects the handwheel to the spindle nut. The cam mechanism allows the torque limiting function to be achieved in a technically simple but effective manner.

[0037] Preferably, the torque limiter is adjustable to allow the mechanism to be adapted to different wires. In addition, the effects of wear can be compensated from time to time.

[0038] The rotation mechanism can include a gear device that is adapted to convert the movement of the wire along the wire path into rotation of the support member relative to the base, thereby obviating the need for a separate drive for rotating the wire engaging mechanism.

[0039] The gear device can be a bevel gear device, which has a ring gear connected to a base and a pinion rotatably mounted on a support, thus realizing a compact rotating mechanism.

[0040] As an alternative to the bevel gear device, a very compact worm drive can be used.

[0041] To allow for a change in the direction of rotation of the wire clutch device when the wire is being pulled through the wheels of the wire clutch device, two mounting positions for the pinion are provided on the support.

[0042] By means of a torque limiter associated with the rotating mechanism, the amount of maximum torque can be very easily limited to the required threshold.

[0043] The torque limiter can be arranged between the gear device and the shaft on which the gear device is provided. In this way, a compact design can be achieved.

[0044] Preferably, the torque limiter is adjustable so as to adapt the mechanism to the different characteristics of the wire.

[0045] According to one embodiment, the torque limiter includes a Belleville spring, which is advantageous because the Belleville spring provides a spring force that changes significantly only within a wide compression range of the spring.

[0046] In an alternative design, the rotating mechanism can include a drive motor, which is mounted on the base and is adapted to rotate the support relative to the base. The drive motor can operate independently of the speed at which the wire is being drawn through the wire clutch device, thus allowing the torque applied to the wire to be controlled independently of the wire withdrawal speed.

[0047] A coupling device can be provided for connecting the motor to the support, thus allowing the motor to be disengaged and engaged when appropriate.

[0048] In a technically simple but reliable design, the coupling includes an applying device for pressing a drive wheel connected to the drive motor against a driven surface associated with the support.

[0049] The device for applying torque to the wire can include a motor current sensor for detecting when excessive torque is being applied to the wire. The motor current is a good indication of the torque being applied.

[0050] The rotating mechanism can be an arm having a wire receiving opening eccentrically arranged with respect to the axis of rotation of the support, thus causing the base to rotate by means of the tension of the wire.

[0051] The present invention also provides a system having a container accommodating a certain amount of wire in the form of a wire coil and a device for applying torsion to the wire. The wire coil is composed of a plurality of wire loops. The device is installed above the wire. The device has a base, a support member, a pair of rollers, and a rotating mechanism. The support member is installed to be rotatable relative to the base about a rotation axis, which is aligned with the wire path extending through the base and the support member. The rollers are installed on the support member and are arranged on opposite sides of the wire path. At least one of the rollers has a wire receiving groove. The rotating mechanism is adapted to rotate the support member relative to the base. The system further includes at least one wire feeder, and these wire feeders are provided downstream of the device for applying torsion to the wire. The device for applying torsion to the wire is conveniently controlled directly by the control of the wire feeder.

[0052] Preferably, two wire feeders are used, namely, a secondary wire feeder provided downstream of the device for applying rotation to the wire and a main wire feeder provided downstream of the secondary wire feeder and at a relatively large distance from the secondary wire feeder. Using two wire feeders allows the wire container to be set at a relatively large distance from the place where the wire is consumed.

[0053] In a preferred embodiment, the wire is a welding wire made of an aluminum alloy containing magnesium. Field tests show that this type of welding wire has tendency internal stress after being stored for a period of time. Therefore, the effect of the device for applying torsion to the welding wire is very beneficial. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In the drawings,

[0055] - Figure 1 a cross-section of a container accommodating a wire coil is shown,

[0056] - Figure 2 a perspective view of the Figure 1 container is shown,

[0057] - Figure 3 a container having entangled wire is shown, Figure 1 of the

[0058] - Figure 4 a side view of the system according to the present invention is shown,

[0059] - Figure 5 a container provided with the device for applying torsion to the wire according to the present invention is shown,

[0060] - Figure 6 a first embodiment of the device for applying torsion to the wire is shown in an exploded view,

[0061] - Figure 7Shows Figure 6 a perspective view of the device shown in

[0062] - Figure 8 Shows Figure 6 a top view of the device of

[0063] - Figure 9 shows a second embodiment of a device for applying torsion to a wire in an exploded view

[0064] - Figure 10 shows in perspective view Figure 9 the device of

[0065] - Figure 11 shows in side view Figure 9 the device of

[0066] - Figure 12 shows in top view Figure 9 the device of

[0067] - Figure 13 shows different gear drives

[0068] - Figure 14 shows a third embodiment of a device for applying torsion to a wire in an exploded view

[0069] - Figure 15 shows in perspective view Figure 14 the device of

[0070] - Figure 16 shows in side view Figure 14 the device of

[0071] - Figure 17 shows in top view Figure 14 the device of

[0072] - Figure 18 shows a fourth embodiment of a device for applying torsion to a wire in an exploded view

[0073] - Figure 19 shows Figure 18 a side view of the device of

[0074] - Figure 20 shows Figure 18 a perspective view of the device of

[0075] - Figure 21 shows Figure 18 a side view of an alternative form of the device of

[0076] - Figure 22 shows a first side view of a fifth embodiment of a device for applying torsion to a wire

[0077] - Figure 23 Shows a second side view of the fifth embodiment,

[0078] - Figure 24 Shows a first perspective view of the fifth embodiment,

[0079] - Figure 25 Shows a second perspective view of the fifth embodiment,

[0080] - Figure 26 Shows a perspective view of the fifth embodiment with a cover added,

[0081] - Figure 27 Shows a part of the mechanism of the fifth embodiment in an exploded view,

[0082] - Figure 28 Shows in a partial sectional view Figure 27 of the component,

[0083] - Figure 29 Shows Figure 28 the perspective view of the device,

[0084] - Figure 30 Shows in a sectional view Figure 28 the mechanism of,

[0085] - Figure 31 Shows in a cross-section the torque limiter used in the device for applying torque to a wire,

[0086] - Figure 32 Shows in a side view Figure 31 the torque limiter of,

[0087] - Figure 33 Shows the torque limiter in a second sectional view,

[0088] - Figure 34 Is Figure 31 the partially cut-away side view of the torque limiter of,

[0089] - Figure 35 Is Figure 31 the second partially cut-away side view of the torque limiter of,

[0090] - Figure 36 Shows in a top view Figure 34 and Figure 35 the torque limiter of,

[0091] - Figure 37 Shows the torque limiter in a perspective view,

[0092] - Figure 38 Shows Figure 37Details XXXVIII,

[0093] - Figure 39 shows a device according to a sixth embodiment of the present invention in a manner similar to Figure 5 -

[0094] - Figure 40 shows details XL of Figure 39 at an enlarged scale,

[0095] - Figure 41 shows the mechanism of Figure 40 at an enlarged scale,

[0096] - Figure 42 shows details XLII of Figure 41 at an enlarged scale,

[0097] - Figure 43 shows an exploded view of the mechanism of Figure 40 -

[0098] - Figure 44 shows a seventh embodiment of the device in a view similar to Figure 39 -

[0099] - Figure 45 shows details XLV of Figure 44 at an enlarged scale,

[0100] - Figure 46 shows an exploded view of an eighth embodiment of the device,

[0101] - Figure 47 shows a perspective view of the eighth embodiment,

[0102] - Figure 48 shows a cross-section through the eighth embodiment, and

[0103] - Figure 49 shows a top view of the eighth embodiment. DETAILED DESCRIPTION

[0104] In Figure 1 , a container 1 is shown, in which a large amount of wire 2 in the form of a coil 3 is accommodated. The coil 3 is composed of a plurality of loops formed by the wire 2.

[0105] The wire 2 can be welding wire. The wire 2 can also be any consumable wire for 3D printing, metallization, etc.

[0106] The wire 2 is drawn out of the container 1 through the upper opening of the container. A lid or dome 4 can be arranged on the top of the container 1, wherein the main purpose of the dome 4 is to prevent contamination of the interior of the container 1 during the period when the wire is being consumed.

[0107] To prevent the loops of the wire from falling inside the coil 3, a retainer 5 is disposed on the upper surface of the coil 3. The main purpose of the retainer 5 is to apply a braking force to the wire and generate friction by the weight of the retainer 5.

[0108] As Figure 3 can be seen, despite the presence of the retainer, some wire loops may still fall inside the coil 3. If the loops become entangled, the wire cannot be withdrawn from the container 1.

[0109] Figure 4 A system according to the present invention is shown, which prevents the loops from falling inside the coil 3 and prevents the loops from becoming entangled.

[0110] An important element of the present invention is a device 10 for applying torsion to the wire 2. Generally, the device 10 rotates the wire about its own axis, thereby canceling some of the residual stresses in the wire and also ensuring that the wire loops remain in their positions within the container 1.

[0111] Downstream of the device 10, a wire feeder 6 may be provided, which advances the wire into a wire guide 7 and towards the place where the wire is consumed, such as towards a welding robot. A main wire feeder may be used near the welding robot, so that the wire feeder 6 becomes a secondary wire feeder.

[0112] The device 10 is arranged close to the container 1. In the illustrated embodiment, the device 10 is disposed on the dome 4 (please refer specifically to Figure 5 ).

[0113] In Figures 6 to 8 a first embodiment of the device 10 for applying torsion to the wire will be described.

[0114] The device 10 includes a base 12 and a support 14. The support 14 is mounted to be rotatable relative to the base 12 about an axis 16 that coincides with the wire path, where the wire 2 is guided through the device 10 along this wire path. A wire inlet guide 15 is attached to the support 14.

[0115] Roller bearings 18 are used to mount the support 14 on the base 12.

[0116] A wire clutch device 20 is mounted on the support 14. Here, the wire clutch device 20 includes two rollers 22 arranged on opposite sides of the wire path 16, where each of the two rollers 22 has a wire receiving groove 24.

[0117] The wire receiving groove 24 has a width and a depth adapted to the dimensions of a specific wire so as to closely engage the wire. When the wire feeder 6 withdraws the wire from the container, the wire passes through the wire path 16 between two adjacent rollers 22, wherein the rollers 22 are driven or rotated by the wire.

[0118] The apparatus 10 further includes a rotating mechanism 26 adapted to rotate the support member relative to the base. Here, the rotating mechanism 26 is formed by a gear device, in particular a bevel gear device 28, which includes an annular gear 30 fixedly provided on the base 12 and a pinion 32 mounted on the support member 14.

[0119] The pinion 32 is connected to one of the rollers 22 via a gear drive 34. Thus, when the roller 22 is driven by the wire, the rotation of the roller is transmitted via the gear device to the pinion 32 engaging the annular gear 30. Thus, when the wire is pulled out through the apparatus 10, the support member 14 rotates relative to the base 12.

[0120] Since the rollers 22 closely engage the wire, the rotation of the support member 14 and accordingly the rotation of the wire clutch device 22 apply torsion to the wire.

[0121] The amount of torsion applied to the wire depends to a large extent on the characteristics of the wire. For some wires, it has been found that a wire clutch device 20 that provides 1.5 revolutions per loop of wire withdrawn can give good results. The number of revolutions per unit length of the withdrawn wire can be adjusted by selecting the size of the rollers 22 and the transmission ratio of the rotating mechanism 26.

[0122] It has been found that the wire clutch device 20 should rotate in the same direction as the wire rotates in the container 1 when withdrawn. As an example, when looking into the container 1 from the top and the wire is withdrawn in the clockwise direction, the wire clutch device 20 should also rotate in the clockwise direction.

[0123] To enable the apparatus 10 to accommodate the two possible winding directions of the wire coil in the container 1, two mounting positions for the pinion 32 are possible. As Figure 8 can be seen, mounting positions 36 are provided on opposite sides for mounting the pinion 32, thereby changing the direction of rotation.

[0124] To prevent excessive torsion from being applied to the wire, a torque limiter can be provided somewhere in the rotating mechanism 20. The torque limiter can be formed by a spring-loaded friction disk or a similar mechanism.

[0125] Figures 9 to 12 A second embodiment of the apparatus 10 is shown. For components known from the first embodiment, the same reference numerals are used and reference is made to the above description.

[0126] The overall difference between the first embodiment and the second embodiment is that, in the second embodiment, the rotating mechanism 26 includes a worm drive 29 formed by a worm wheel 31 fixedly provided on the base 12 and a screw gear 33 mounted on the support member 14.

[0127] The screw gear 33 is connected to one of the rollers 22 via a gear drive 34. Thus, when the roller 22 is driven by the wire, the rotation of the roller is transmitted via the gear device to the screw gear 33 engaged with the worm wheel 31, and when the screw gear 33 is rotated, it rotates the support member 14 relative to the base 12.

[0128] In a manner similar to the first embodiment, the direction of rotation can be reversed by mounting the gear drive 34 on the opposite side of the support member 14.

[0129] The gear drive 34 can also be switched by an electric motor, enabling the support member 14 to rotate relative to the base 12 independently of the fixed transmission ratio of the wire release relative to the rotation of the support member.

[0130] The second embodiment allows for the convenient change of the transmission ratio from the roller 22 to the screw gear 33, as will be described below with reference to Figure 13 as follows.

[0131] In Figure 13 a, a small-diameter container 1 with a small-diameter wire coil 3 is shown. To convert the rotation of the roller 22 into a suitable rotation of the screw gear 33, a large gear 34a (see Figure 13 b) is mounted on the axis on which the roller 22 is mounted, where the gear 34a drives a pinion 34c that is drivingly connected to the screw gear 33 via an intermediate gear 34b.

[0132] In Figure 13 c, a medium-diameter container 1 with a medium-diameter wire coil 3 is shown. To convert the rotation of the roller 22 into a smaller rotation of the screw gear 33 (per unit length of the drawn wire), a medium gear 34a (see Figure 13 d) is mounted on the axis on which the roller 22 is mounted, where the gear 34a drives a medium gear 34c that is drivingly connected to the screw gear 33 via an intermediate gear 34b.

[0133] In Figure 13 e, a large-diameter container 1 with a large-diameter wire coil 3 is shown. To convert the rotation of the roller 22 into an even smaller rotation of the screw gear 33, a pinion 34a (see Figure 13 f) is mounted on the axis on which the roller 22 is mounted, where the gear 34a drives a large gear 34c that is drivingly connected to the screw gear 33 via an intermediate gear 34b.

[0134] The intermediate gear 34b is mounted in a sliding guide 35 which allows for a quick adaptation of the gear ratio to different packaging sizes (and the corresponding ring diameters inside the packaging).

[0135] The dust cover 17 encloses the device 10 to prevent dust and dirt from entering the device 10 and the container 1.

[0136] Figures 14 to 16 A third embodiment of the device 10 is shown. For components known from the first and second embodiments, the same reference numerals are used and reference is made to the above description.

[0137] The overall difference between the first and second embodiments and the third embodiment is that the first and second embodiments are "passive" devices in which the torsion applied to the wire is generated by the movement of the wire itself, while in the second embodiment, the torsion is actively generated by a motor.

[0138] The third embodiment also uses a worm drive 29 formed by a worm wheel 31 and a worm gear 33. Here, the worm wheel 31 is fixedly connected to the support 14, while the worm gear 33 is mounted on the base 12.

[0139] A motor 40 is provided for driving (via a suitable reduction gear) the worm gear 33.

[0140] The rollers 22 are mounted rotatably on the support 14. The rollers 22 are biased against each other with an adjustable force.

[0141] In the third embodiment, the device 10 is controlled by a controller which can be incorporated into the wire feeder 6. The controller can also be implemented separately.

[0142] When the wire is withdrawn from the container 1, the electric motor 40 is operated to rotate the wire clutch device 20 in the correct direction, thereby applying torsion to the wire.

[0143] The amount of rotation of the wire clutch device 20 per unit length of the withdrawn wire can be very conveniently controlled via the controller. To prevent excessive torsion from being applied to the wire, the motor current of the motor 40 can be controlled. If excessive torsion is generated in the wire, the motor current increases because a greater force is required to rotate the wire. In such an event, the operating speed of the motor 40 can be reduced or stopped, or the biasing device 46 can be deactivated so that the support 14 can rotate freely, thereby releasing the torsional tension in the wire. Subsequently, the biasing device 46 can be reactivated and the operation of the motor 40 can be resumed.

[0144] The advantage of the third embodiment is that many of its components can be used both for the passive device according to the second embodiment and for the active device according to the third embodiment.

[0145] Figures 17 to 20 A fourth embodiment of the device 10 is shown. For components known from the previous embodiments, the same reference numerals are used and reference is made to the above description.

[0146] The overall difference between the third embodiment and the fourth embodiment is that in the fourth embodiment, there is no meshing gear connection (and thus a form - fit connection) between the motor and the support, but a friction - based connection.

[0147] Here, the rotation mechanism 26 includes a drive motor 40 (an electric motor) that drives a drive wheel 42. The electric motor 40 and the drive wheel 42 are mounted together on a carrier 44, and the carrier 44 is pivotally connected to the base 12.

[0148] An application device 46 in the form of a solenoid is mounted on the base 12, and the application device 46 is adapted to push the carrier 44 together with the motor 40 and the drive wheel 42 in the direction towards the support 14. More specifically, the application device 46 presses the drive wheel 42 against a cylindrical driven surface 48 of the support 14.

[0149] The drive wheel 42 may be provided with an O - ring 50 or some other friction - enhancing element to ensure that the support 14 can be rotated by the motor 40.

[0150] The wire - engaging device 20 of the fourth embodiment corresponds essentially to the first embodiment, since the wire - engaging device 20 of the fourth embodiment includes two rollers 22 that press against each other and against the wire passing between them. A biasing device 52 is provided here, and the biasing device 52 allows the force with which the two rollers press against each other to be changed.

[0151] When the wire is withdrawn from the container 1, the electric motor 40 is operated to rotate the wire - engaging device 20 in the correct direction, thereby applying the desired torsional force to the wire. At the same time, the biasing device 46 is activated to ensure that the power of the motor 40 is transmitted to the support 14.

[0152] In Figure 21 a Figures 17 to 20 an alternative of the embodiment is shown. Here, the drive wheel 42 is connected to the support 14 via a belt or a rubber ring 60, thus eliminating the need for a biasing device.

[0153] In Figures 22 to 30In [the figure], another embodiment of a device for applying torsion to a wire is shown. For elements known from the previous embodiment, the same reference numerals are used and reference is made to the above description.

[0154] Figures 22 to 30 The embodiment of [the device] is equivalent to Figures 6 to 13 the embodiment of [the device] because the movement of the wire through the wire path 16 causes the rotation of the roller 22, and the rotation of the roller 22 is in turn converted into the rotation of the support 14 relative to the base 12.

[0155] Here, the gear drive 34 includes a shaft 70 on which one of the rollers 22 is mounted and one of the two gears 72 for synchronizing the rotation of the two rollers 22. In addition, a gear 74 is mounted on the shaft 70, and the gear 74 meshes with an additional gear, which ultimately drives a worm gear 32 engaged in the worm wheel 31.

[0156] A torque limiter 76 is provided in the torque transmission path between the shaft 70 and the gear 34.

[0157] Generally speaking, the torque limiter 76 prevents excessive torque from being transmitted from the shaft 70 to the gear 74.

[0158] The torque limiter 76 includes a pressure ring 78, a spring 80 which is a Belleville spring here, an adjusting screw 82 and a locking mechanism 84.

[0159] The gear 74 is arranged adjacent to a shoulder 84 of the shaft 70. By screwing the adjusting screw 82 onto the shaft 70, the spring 80 is biased by the adjusting screw 82 against the pressure ring 78, and the pressure ring 78 in turn presses the gear 74 against the shoulder 84. Thus, a frictional force is generated that allows torque transmission from the shaft 70 to the gear 74 up to a predetermined threshold.

[0160] By adjusting the adjusting screw 82 on the shaft 70, the allowable torque transmission level can be adjusted. The locking mechanism 86 allows the adjusting screw 82 to be locked in its position once the desired torque transmission level is reached.

[0161] The torque limiter reliably ensures that no excessive torsion will be generated that will subsequently be applied to the wire.

[0162] Figures 31 to 38 Details of the biasing device 52 for changing the force with which the rollers 22 press against each other are shown.

[0163] The biasing device 52 is used to apply a force to a rod 53, and the rod 53 in turn causes a force to be generated that biases the rollers 22 towards each other.

[0164] The biasing device 52 includes a draw bar 90 which is connected to the rod 53 and to which a traction force can be applied by means of the biasing device 52, wherein the biasing device 52 is supported on a support 92.

[0165] The support 92 has the form of a hook into which a wedge-shaped squeezing member 94 engages (see in particular Figures 31 to 37 ).

[0166] A nut 96 is supported on the squeezing member 94 and is threadedly engaged with the draw bar 90. The nut 96 can be rotated by means of a handwheel 98 which is connected to the nut 96 by means of a cam mechanism 100. The cam mechanism 100 includes a cam surface 102 and a drive pin 104, the cam surface 102 being provided in the nut 96 and the drive pin 104 being supported in the handwheel 98 so as to be displaceable in a direction parallel to the axis of rotation of the handwheel 98. The pressure pin 104 is engaged by a squeezing pad 106 on the side thereof facing away from the cam surface 102, and the squeezing pad 106 is in turn biased towards the pressure pin 104 by a stack of springs 108. Here, Belleville springs are used.

[0167] The springs 108 are capped in a preloaded state by means of an adjusting wheel 110, and the axial position of the springs 108 can be adjusted by means of a set screw 112. The set screw 112 can be accessed after removing the cover 114.

[0168] By rotating the set screw 112, the preloading of the springs 108 can be adjusted. By adjusting this preloading, the maximum torque that can be transmitted to the cam surface 102 of the nut 96 by the rotation of the squeezing pin 104 can be adjusted. See Figure 38 , the clockwise rotation of the handwheel 98 will drive the rotation of the nut 96 as long as the required force does not cause the squeezing pin 104 to slide upwards on the cam 102 against the force of the springs 108 and eventually leave the cam surface. In the opposite direction, the squeezing pin 104 slides downwards on the cam surface 102 and engages at an end stop, thus reliably driving the nut 96.

[0169] When the desired level of torque transmission from the handwheel 98 to the nut 96 has been adjusted by means of the set screw 112, the locking screw 116 is tightened.

[0170] In Figures 39 to 43 , a further embodiment of a device for applying a torque to a wire is shown. For elements known from the previous embodiment, the same reference numerals are used and reference is made to the above description.

[0171] Figures 39 to 43 The overall difference between the embodiment of Figures 39 to 43In the embodiment, the support member 14 with the roller 22 rotates only under the action of the wire 2. There is no motor for rotating the support member, and there is no gear device for converting the rotation of the roller 22 into the rotation of the support member.

[0172] Here, the support member 14 rotates by means of an arm 120 which has a wire receiving opening 122 eccentrically arranged with respect to the rotation axis of the support member 14. When the wire 2 is held in the container 1 in the form of a coil, any traction force acting between the portion of the wire entering between the rollers 22 and the portion of the wire received in the form of a coil generates a force at the wire receiving opening 122 having a component directed in the circumferential direction.

[0173] Figure 44 and Figure 45 shows in Figures 39 to 43 an alternative of the embodiment. The difference between this alternative embodiment and the previous embodiment is that in this alternative, a flexible wire guide 130 is used, which is held in a tube 132 here to ensure that the end of the wire 2 leaving the wire guide 130 is eccentrically arranged with respect to the rotation axis of the support member 14.

[0174] In Figures 46 to 49 is shown yet another embodiment of a device for applying torsion to the wire. For the components known from the previous embodiment, the same reference numerals are used and reference is made to the above description.

[0175] In Figures 46 to 49 the embodiment, the device 10 has an electric motor 140 for actively rotating the roller 22. Downstream of the roller 22 are provided two straightening roller sets 142 for straightening the wire. The roller 22 driven by the motor 140 is used to push the wire through the straightening roller sets 142.

[0176] The motor 140 is powered by means of a sliding contact 144 concentrically arranged with respect to the rotation axis of the device 10.

Claims

1. A device for applying torsion to a wire, the device having a base, a support member, a wire engaging device, and a rotation mechanism, the support member being mounted to be rotatable relative to the base about a rotation axis that is aligned with a wire path extending through the base and the support member, the wire engaging device being mounted on the support member and adapted to engage a wire being guided along the wire path, the rotation mechanism being adapted to rotate the support member relative to the base. Among them, The wire engaging device is a pair of rollers mounted on the support member, the rollers being arranged on opposite sides of the wire path, at least one of the rollers having a wire receiving groove, wherein a biasing device is provided for biasing the two rollers against each other, and wherein the biasing device includes a handwheel for applying a fastening torque to a biasing mechanism, and a torque limiter is provided in the torque path from the handwheel to the biasing mechanism.

2. The device according to claim 1, wherein A spring-loaded cam mechanism is provided that connects the handwheel to a spindle nut.

3. The device according to claim 1 or claim 2, wherein The torque limiter is adjustable.

4. The device according to claim 1 or claim 2, wherein, The rotation mechanism includes a gear device adapted to convert the movement of the wire along the wire path into rotation of the support member relative to the base.

5. The device according to claim 4, wherein The gear device is a bevel gear device having an annular gear connected to the base and a pinion rotatably mounted on the support member.

6. The device according to claim 5, wherein, Two mounting positions for the pinion are provided on the support member.

7. The apparatus according to claim 4, wherein The gear device is a worm drive.

8. The device according to any one of claims 5 to 7, wherein An intermediate gear is provided and is mounted in a sliding guide.

9. The apparatus according to claim 4, wherein, The rotation mechanism is associated with the torque limiter.

10. The apparatus according to claim 9, wherein, The torque limiter is provided between the gear device and the shaft on which the gear device is provided.

11. The device according to claim 10, wherein, The torque limiter is adjustable.

12. The device according to claim 9 or claim 10, wherein, The torque limiter includes a Belleville spring.

13. The device according to claim 1, wherein, The rotation mechanism includes a drive motor mounted on the base and adapted to rotate the support member relative to the base.

14. The apparatus according to claim 13, wherein, A coupling device is provided for connecting the motor to the support member.

15. The device according to claim 13 or claim 14, wherein, The coupling includes an applying device for pressing a drive wheel connected to the drive motor against a driven surface associated with the support member.

16. The device according to claim 13, wherein, A motor current sensor is provided.

17. The apparatus according to claim 1, wherein The rotation mechanism is an arm having a wire receiving opening that is eccentrically arranged relative to the rotation axis of the support member.

18. The device according to claim 1, wherein, A wire straightener is provided at the support member.

19. A system having a container and a device for applying torsion to a wire according to claim 1, the container containing a quantity of wire in the form of a wire coil, the wire coil being composed of a plurality of wire loops, the device being mounted above the wire, the system further including at least one wire feeder provided downstream of the device for applying torsion to the wire.

20. The system according to claim 19, wherein A retainer is provided on the wire coil of the wire.

21. The system according to claim 20, wherein, The wire feeder provided downstream of the device for applying rotation to the wire is a secondary wire feeder, and wherein a main wire feeder is provided downstream of the secondary wire feeder.

22. A system having a container and a device for applying torsion to a wire according to claim 1, the container containing a quantity of wire in the form of a wire coil, the wire coil being composed of a plurality of wire loops, the device being mounted above the wire, the rotation mechanism including a drive motor for rotating the support relative to the base, the system further including at least one wire feeder and a controller, the wire feeder being provided downstream of the device for applying torsion to the wire, the controller being for controlling the rotational speed of the drive motor of the rotation mechanism, the controller including a torque detection for limiting the torsion applied to the wire.

23. The system according to claim 22, wherein, The wire is a welding wire made of an aluminum alloy containing magnesium.

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