Wire feed system with built-in rotary power connector
The wire feeding system with a built-in rotary power connector solves the problem of wear on welding cables caused by torsion and strain, extending cable life and making replacement easier, while improving the stability of the welding process.
Patent Information
- Application Number
- CN202510617401.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2025-04-29
- Filing Date
- 2025-05-14
- Publication Date
- 2025-11-18
AI Technical Summary
In conventional wire feeding systems, welding power cables are prone to wear due to torsion and strain during the welding process, which affects their service life, and replacing cables requires machine downtime.
The wire feeding system, which employs a built-in rotary power connector, allows the welding power cable and power pins to rotate relative to the wire feeder, reducing torsion and strain, and providing power, gas, and electrode wire supply through the rotary power connector.
It reduces wear on welding cables, extends their service life, simplifies cable replacement, and improves the continuity of the welding process.
Smart Images
Figure CN120962055A_ABST
Abstract
Description
[0001] Cross Reference to Related Applications
[0002] This application is a non-provisional patent application of U.S. Provisional Patent Application No. 61 / 647,959, filed May 15, 2024, entitled “Wire Feeding Systems With Built-In Rotating Power Connectors,” which is incorporated by reference herein in its entirety. TECHNICAL FIELD
[0003] The present disclosure relates generally to electrode wire feeding systems, and more particularly to electrode wire feeding systems with built-in rotating power connectors. BACKGROUND
[0004] Conventional wire feeding systems feed welding wire to a welding torch or robotic arm in order to perform a weld. Typically, the welding wire is fed through a power cable that provides current, shielding gas, and electrode wire to the welding torch and includes two fixed connections: one end of the power cable is fastened to the wire feeder by a power pin, and the other end is fastened to the welding torch. SUMMARY
[0005] Electrode wire feeding systems with built-in rotating power connectors are disclosed, substantially as illustrated by and described in connection with at least one of the figures, as more fully described in the claims. BRIEF DESCRIPTION OF DRAWINGS
[0006] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0007] Figure 1 An example welding-type system is illustrated in accordance with aspects of the present disclosure.
[0008] Figure 2 is a block diagram of an example rotating power connector of an example wire feeder of Figure 1
[0009] Figure 3 is a block diagram of an example rotating power connector of an example wire feeder of Figure 1
[0010] Figure 4 is a block diagram of an example rotating power connector of an example wire feeder of Figure 1
[0011] The drawings are not necessarily to scale. Like numbers refer to like elements throughout. On occasion, where same elements occur in more than one figure, the elements are designated by lettered suffixes as DETAILED DESCRIPTION
[0012] For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the examples illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the claims is intended. Alterations and further modifications of the illustrated examples, and such further applications of the principles of the present disclosure illustrated herein are contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0013] The present disclosure relates generally to electrode wire feeder systems, and more particularly to electrode wire feeder systems having a built-in rotary power connector. In particular, example electrode wire feeder systems including a rotary power connector are disclosed. Example wire feeder systems having a built-in rotary power connector are disclosed that provide a mechanical and electrical connection between the wire feeder and a power pin attached to a welding power cable and allow the power pin and welding power cable to rotate relative to the wire feeder. The example wire feeder systems having a built-in rotary power connector provide welding power, shielding gas, and electrode wire to a welding torch via the rotary power connector.
[0014] During welding, as the welding torch is manipulated by a user or robot, the welding power cable can twist, be stressed, and / or strained as the torch is moved. Over time, this can cause wear on the welding power cable and can cause failure of the cable. Additionally, the twisting and / or turning during torch manipulation can also cause stress and / or strain on the wire liner that extends from the power pin of the power welding cable through the torch. Furthermore, replacing the welding power cable requires downtime and removal of various connectors and components in order to replace the cable.
[0015] The present disclosure provides a wire feeder system having a built-in rotary power connector that receives a power pin of a welding torch. The present disclosure advantageously allows the power pin of the welding torch to rotate at the wire feeder in order to minimize the twisting, stress, and strain on the welding power cable and wire liner.
[0016] The disclosed example welding-type systems provide an electrode wire feeder system with a built-in rotating power connector to accept a power pin from a welding torch. Additionally, the disclosed example welding-type systems provide a wire feeder system that minimizes twisting of a welding power cable relative to a welding torch. The disclosed example welding-type systems provide a connector that delivers shielding gas, welding current, and electrode wire to a welding torch. The disclosed example welding-type systems allow a power pin and welding power cable to rotate relative to a wire feeder. The disclosed example welding wire feeder system minimizes movement of a welding wire bushing during a welding process due to movement of a welding torch.
[0017] As used herein, the word "exemplary" means "serving as an example, instance, or illustration." The examples described herein are not the only examples possible. It is appreciated that
[0018] The disclosed example wire feeder for providing electrode wire to a welding torch includes one or more drive rolls configured to retract or advance electrode wire and a rotating power connector including an outer portion having a hollow bore and an inner sleeve within the hollow bore. In some examples, the inner sleeve is configured to accept a power pin of a welding torch aligned with the one or more drive rolls, conduct power to the power pin, and allow the power pin to rotate relative to the outer portion, wherein the outer portion is fixed within the wire feeder.
[0019] In some example wire feeders, the power pin is configured to slide into and out of the inner sleeve. Some example wire feeders include one or more fasteners to secure the power pin within the inner sleeve. In some example wire feeders, the rotating power connector is further configured to deliver shielding gas to the welding torch through the power pin. In some example wire feeders, the rotating power connector includes a current path from the wire feeder to the welding torch. In some example wire feeders, the one or more drive rolls are configured to advance electrode wire to the welding torch through the rotating power connector or retract electrode wire.
[0020] An example welding system includes a welding torch including a power pin and a wire feeder configured to provide an electrode wire to the welding torch and including one or more drive rolls configured to retract or advance the electrode wire and a rotary power connector between the one or more drive rolls and the power pin of the welding torch to provide an electrical connection from the wire feeder to the welding torch, and the rotary power connector includes an outer portion having a hollow bore and an inner sleeve within the hollow bore, wherein the inner sleeve is configured to receive the power pin of the welding torch aligned with the one or more drive rolls and allow the power pin to rotate relative to the outer portion, and wherein the outer portion is fixed within the wire feeder.
[0021] Some example welding systems include a welding power cable connected between the power pin and the welding torch, wherein the welding power cable mitigates strain at the wire feeder during welding. In some example welding systems, the one or more drive rolls are configured to advance the electrode wire to the welding torch or retract the electrode wire through the rotary power connector. In some example welding systems, the wire feeder includes one or more fasteners to engage the power pin within the inner sleeve. In some example welding systems, a perimeter of the outer portion of the rotary power connector is fixed within the wire feeder. In some example welding systems, the power pin is configured to slide into and out of the inner sleeve. In some example welding systems, the rotary power connector is configured to deliver a shielding gas through the power pin to the welding torch. In some example welding systems, the rotary power connector includes a current path from the wire feeder to the welding torch.
[0022] As used herein, the terms "first" and "second" can be used to enumerate different components or elements of the same type, and do not necessarily imply any particular order.
[0023] As used herein, the words "exemplary" and "example" mean "serving as an example, instance, or illustration.” The examples described herein are not the only examples that can be used to implement the present application, and are not necessarily to be construed as preferable or advantageous over other examples. Furthermore, the terms "a
[0024] As used herein, the term "welding-type system" includes any device capable of supplying power suitable for welding, plasma cutting, induction heating, air carbon arc cutting (e.g., CAC-A), and / or hot wire welding / preheating (including laser welding and laser cladding), including inverters, converters, choppers, resonant power supplies, quasi-resonant power supplies, and the like, as well as control circuitry and other ancillary circuitry associated therewith.
[0025] As used herein, the term "welding-type power" refers to power suitable for welding, plasma cutting, induction heating, CAC-A, and / or hot wire welding / preheating (including laser welding and laser cladding). As used herein, the terms "welding-type power supply" and / or "power supply" refer to any device capable of supplying power to welding, plasma cutting, induction heating, CAC-A, and / or hot wire welding / preheating (including laser welding and laser cladding) when electrical power is applied thereto, including but not limited to inverters, converters, resonant power supplies, quasi-resonant power supplies, and the like, as well as control circuitry and other ancillary circuitry associated therewith.
[0026] As used herein, the terms "torch," "welding torch," "welding tool," or "welding-type tool" refer to a device configured to be manipulated for performing welding-related tasks, and can include a hand-held torch, a robotic torch, a welding gun, a gouging tool, a cutting tool, or other device for producing a welding arc.
[0027] As used herein, the terms "welding mode," "welding process," "welding-type process," or "welding operation" refer to the type of process or output used, such as current control (CC), voltage control (CV), pulsed gas metal arc welding (GMAW), flux cored arc welding (FCAW), gas tungsten arc welding (GTAW, e.g., TIG), shielded metal arc welding (SMAW), spray transfer, short circuit, CAC-A, gouging process, cutting process, and / or any other type of welding process.
[0028] Figure 1 An example welding-type system 100 is illustrated. Figure 1 An example welding-type system 100 includes a power supply 110 for delivering welding power, a gas source 120 for delivering shielding gas, and a welding wire feeder 130 for providing welding wire for certain types of welding. A welding torch 140, such as a gas tungsten arc welding (GTAW) torch, a wire-fed welding torch (e.g., a torch for performing gas metal arc welding (GMAW), flux cored arc welding (FCAW), etc.), a plasma cutting torch, a carbon arc cutting torch, a gouging torch, etc., can be connected to the wire feeder 130.
[0029] In some examples, the power supply 110 provides power to the wire feeder 130 in order to supply an electrode wire to the welding torch 140 for various welding applications (e.g., GMAW welding, flux cored arc welding (FCAW)). The power supply 110 receives shielding gas from the gas source 120 and routes the shielding gas to the wire feeder 130 via the cable 112. In some examples, the wire feeder 130 is part of or integrated into the welding power supply 110. The example welding torch 140 includes a welding torch head 142 and a welding torch body 144.
[0030] The power supply 110 includes a controller (not shown) to control the operation of the power supply 110. The controller can also include interface circuitry for communicating data to other devices in the system, such as the wire feeder 130 or other welding-type devices. For example, in some cases, the power supply 110 can communicate wirelessly with other welding devices within the welding system. Further, in some cases, the power supply 110 communicates with other welding devices using a wired connection, such as for data communication via a network (e.g., Ethernet, 10baseT, 10base100, etc.) using a network interface controller (NIC).
[0031] The gas source 120 can provide shielding gas to the power supply 110. The power supply 110 provides welding power and shielding gas to the wire feeder 130. The wire feeder 130 receives the welding power and shielding gas from the power supply 110 and then provides the welding power, shielding gas, and electrode wire to the welding torch body 144 of the welding torch 140 for delivery to the welding torch head 142 via the welding power cable 150.
[0032] The rotating power connector 132 of the wire feeder 130 can provide shielding gas, current, and electrode wire to the welding torch 140. The rotating power connector 132 can be mounted in an opening or outlet in the wire feeder 130. Power pins (not shown, but described further below) are attached to the welding power cable 150 of the welding torch 140 and can be inserted into the rotating power connector 132 to allow the gas, current, and welding wire to be delivered to the welding torch 140 through the welding power cable 150. Figures 2 to 4 Further description is provided below.
[0033] In some examples, as the welding torch 140 is manipulated, movement of the welding torch 140 affects the stress and / or strain on the welding power cable 150. For example, the welding power cable 150 twists, turns, and / or bends based on the movement of the welding torch 140. The rotating power connector 132 mounted in the wire feeder 130 allows the welding power cable 150 to turn at the wire feeder 130 in order to minimize the twisting, turning, and / or bending of the welding power cable 150.
[0034] Figure 2 yes Figure 1 A block diagram of an example rotary power connector 132 for an example wire feeder. The rotary power connector 132 includes an outer portion 133 having a hollow hole 134 (also described below). Figure 4 (Description to follow). The inner sleeve 135 is located within the hollow hole 134 and receives the electrode wire 210 on a first side and the welding power cable 150 attached to it on a second side (e.g., in...). Figure 1 The power pin 152 (described in the diagram) is fixed within the wire feeder 130, and the inner sleeve 135 is rotatable. Once the power pin 152 is inserted, it is secured within the inner sleeve 135, allowing rotation of the power pin 152 relative to the wire feeder 130. An electrode wire 210 is inserted into the inner sleeve 135 at the end opposite to the power pin 152. The electrode wire 210 can advance through the inner sleeve 135 of the rotating power connector 132 and into the power pin 152, which connects to the soldering power cable 150.
[0035] In some examples, as a non-limiting example, the rotary power connector 132 is made of a conductive material, such as brass or copper. The outer portion 133 of the rotary power connector 132 may be integrated into the wire feeder 130, such that the outer portion 133 remains fixed. In some examples, the rotary power connector 132 may be coupled to the wire feeder 130 and / or attached to other internal components of the wire feeder 130, such that the outer portion 133 does not move relative to the wire feeder 130. In some examples, the periphery of the outer portion 133 of the rotary power connector is fixed to the wire feeder 130 and / or other components of the wire feeder 130 to attach the rotary power connector to the wire feeder 130. In some examples, the inner sleeve 135 is fastened to the outer portion 133 and / or other components of the wire feeder 130. For example, the inner sleeve 135 may be fastened to the outer portion 133 such that the inner sleeve 135 can rotate while the outer portion 133 remains fixed within the wire feeder 130. In some examples, the outer portion 133 includes one or more electrical contacts disposed within the outer portion 133 and / or the inner sleeve 135 to provide electrical connections between the outer portion 133 and the inner sleeve and / or between the inner sleeve 135 and the power pin 152.
[0036] The power pin 152 can be fastened to the inner sleeve 135 of the rotary power connector. In some examples, the power pin 152 is fastened using one or more of the following: clamps, clips, screws, nuts, bolts, rivets, pins, washers, etc. In some examples, one or more bearings (not shown) may be placed within the outer portion 133 and / or the inner sleeve 135 to provide stability while allowing rotation of the inner sleeve 135 and / or the power pin 152.
[0037] Figure 3 is Figure 1 a cross-sectional side view of an example wire feeder of an example welding-type system. Figure 4 is Figure 1 a perspective view of an example wire feeder of an example welding-type system of FIG. 1. The wire feeder 130 includes a rotary power connector 132, a knob 137 for tightening a power pin 152 of a welding torch 140, and a drive roll 138 for advancing or retracting an electrode wire toward and away from the welding torch 140. The rotary power connector 132 and the power pin 152 can be composed of an electrically conductive material, such as copper and / or brass. The rotary power connector 132 is built into the wire feeder 130 and includes a hollow bore or aperture (as described above with respect to FIG. 1) to receive the power pin 152. The power pin 152 of the welding power cable 150 is located within the rotary power connector 132 and is configured to couple the rotary power connector 132 to the welding power cable 150. Figure 2
[0038] The electrode wire 210 inserted at the wire feeder 130 at a first end of the wire feeder 130 can be guided to the drive roll 138 using a wire guide (not shown) and through the rotary power connector 132 and the power pin 152 to the torch head 142 of the welding torch. At a second end of the wire feeder, a wire bushing 154 can be inserted into the power pin 152 of the welding torch 140 and extend through the length of the welding power cable 150 and the welding torch 140. In some examples, the wire bushing 154 is fixed at the power pin side of the welding power cable 150 and / or at the end of the welding torch 140. A portion of the wire bushing 154 can be external to the power pin 152 such that the wire bushing 154 can receive the electrode wire 210 once the power pin 152 is inserted into the rotary power connector 132 within the wire feeder 130.
[0039] The power pin 152 with the wire bushing 154 can be inserted into the internal sleeve 135 of the rotary power connector 132 of the wire feeder 130 as described above with respect to FIG. 1. The power pin 152 of the welding power cable 150 is configured to couple the rotary power connector 132 to the welding power cable 150 in order to deliver shielding gas, welding power, and electrode wire to the welding torch 140 and can be located within the internal sleeve of the rotary power connector 132. The power pin 152 is rotatable within the rotary power connector 132. The power pin 152 is fastened to the internal sleeve 135 of the rotary power connector 132 in order to allow the power pin 152 to rotate with the internal sleeve 135, thus allowing any strain and / or tension in the welding power cable 150 to be released. Figure 2
[0040] In some examples, the power pin 152 is inserted into the inner sleeve 135 of the rotary power connector 132 and secured using a clamping mechanism, a gripping mechanism, a securing mechanism, or a locking mechanism in order to secure the power pin 152 to the rotary power connector 132. For example, the knob 137 can be used to tighten a wing nut clamping mechanism to secure the power pin 152 to the rotary power connector 132. In some other examples, the knob 137 can be used to tighten another type of securing mechanism to secure the power pin 152 to the rotary power connector 132 while allowing the power pin 152 to rotate with the inner sleeve 135. Once inserted, the wire liner 154 can receive the electrode wire 210, which can be advanced through the rotary power connector 132, into the power pin 152, and to the welding torch 140 for welding use using a drive roll.
[0041] As used herein, “and / or” means any one or more of the items in the list of items. As an example, “x and / or y” means any one or more of the elements comprising the set {(x), (y), (x, y)}. In other words, “x and / or y” means “one or both of x and y”. As another example, “x, y, and / or z” means any one or more of the elements comprising the set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, “x, y, and / or z” means “one or more of x, y, and z”. As used herein, the term “exemplary” means serving as a non-limiting example, instance, or illustration. As used herein, the terms “e.g.,” and “for example” set off a list of one or more non-limiting examples, instances, or illustrations. As used herein, circuitry is “operable” to perform a function whenever the circuitry comprises hardware and code necessary to perform the function, if any, regardless of whether performance of the function is disabled or not enabled (e.g., by an operator configurable setting, factory trim, etc.).
[0042] Although the present method and / or system has been described with reference to certain implementations, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the present method and / or system. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. For example, the blocks and / or components of disclosed examples can be combined, divided, re-arranged, and / or otherwise modified. Therefore, the present method and / or system are not limited to the particular implementations disclosed. Instead, the present method and / or system will include all implementations falling within the scope of the appended claims, both literally and under the doctrine of equivalents.
Claims
1. A wire feeder for providing an electrode wire to a welding torch, comprising: one or more drive rolls configured to retract or advance the electrode wire; a rotating power connector, the rotating power connector comprising: an outer portion having a hollow bore; and an inner sleeve within the hollow bore, wherein the inner sleeve is configured to receive a power pin of the welding torch aligned with the one or more drive rolls, conduct power to the power pin, and allow the power pin to rotate relative to the outer portion, wherein the outer portion is fixed within the wire feeder.
2. The wire feeder of claim 1, wherein, the power pin is configured to slide into and out of the inner sleeve.
3. The wire feeder of claim 1, further comprising one or more fasteners to secure the power pin within the inner sleeve.
4. The wire feeder of claim 1, wherein, the rotating power connector is further configured to deliver shielding gas through the power pin to the welding torch.
5. The wire feeder of claim 1, wherein, the rotating power connector comprises a current path from the wire feeder to the welding torch.
6. The wire feeder of claim 1, wherein, the one or more drive rolls are configured to advance the electrode wire through the rotating power connector to the welding torch or retract the electrode wire.
7. A welding system, comprising: a welding torch, the welding torch comprising a power pin; a wire feeder configured to provide an electrode wire to the welding torch and comprising: one or more drive rolls configured to retract or advance the electrode wire; a rotating power connector between the one or more drive rolls and the power pin of the welding torch to provide an electrical connection from the wire feeder to the welding torch, and the rotating power connector comprising: an outer portion having a hollow bore; and an inner sleeve within the hollow bore, wherein the inner sleeve is configured to receive the power pin of the welding torch aligned with the one or more drive rolls and allow the power pin to rotate relative to the outer portion, wherein the outer portion is fixed within the wire feeder.
8. The welding system of claim 7, further comprising a welding power cable connected between the power pin and the welding torch, wherein, the welding power cable mitigates strain at the wire feeder during welding.
9. The welding system of claim 7, wherein, the one or more drive rolls are configured to advance the electrode wire through the rotating power connector to the welding torch or retract the electrode wire.
10. The welding system of claim 7, wherein, the wire feeder comprises one or more fasteners to engage the power pin within the inner sleeve.
11. The welding system of claim 7, wherein, a circumference of the outer portion of the rotating power connector is fixed within the wire feeder.
12. The welding system of claim 7, wherein, the power pin is configured to slide into and out of the inner sleeve.
13. The welding system of claim 7, wherein, the rotating power connector is configured to deliver shielding gas through the power pin to the welding torch.
14. The welding system of claim 7, wherein, the rotating power connector comprises a current path from the wire feeder to the welding torch.