Welding wire length measuring device and wire feeder

Abstract

The utility model relates to a welding wire length measuring device and a wire feeder. The welding wire length measuring device comprises a signal transmitting assembly, a signal receiving assembly and a processor. The signal transmitting assembly is used for being installed on a wire feeding roller of the wire feeder and outputting a to-be-detected signal along with rotation of the wire feeding roller. The signal receiving assembly is used for being installed on a body of the wire feeder, receiving the to-be-detected signal and generating a displacement sensing signal according to the to-be-detected signal. And the processor is connected with the signal receiving assembly and is configured to obtain the displacement sensing signal and determine the feeding size of the welding wire according to the displacement sensing signal and the diameter of the wire feeding roller. According to the method, the feeding length of the welding wire can be accurately measured, so that the production benefit can be accurately calculated, the device compatibility is high, the cost control and the production plan can be optimized, and the welding quality and the production efficiency are ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding equipment, in particular to a welding wire length measuring device and a wire feeder. BACKGROUND

[0002] Gas metal arc welding, as one of the commonly used welding technologies, continuously feeds welding wire as a consumable electrode, and heats and melts the welding wire and base material through an electric arc, while using inert gas (such as argon) as a shielding gas to prevent oxidation and contamination of the welding area. The welding wire refers to a metal wire used as a filler metal or serving as a conductor during welding.

[0003] However, when welding wire consumption is counted during production, the current during welding is often used to estimate the consumption of the welding wire, and the deviation of the estimation result from the actual use result is relatively large, so that the production benefit cannot be accurately calculated. CONTENT OF THE UTILITY MODEL

[0004] Based on this, the embodiments of the present application provide a welding wire length measuring device and a wire feeder, which can accurately measure the feeding length of the welding wire, so as to accurately calculate the production benefit, thereby not only having high equipment compatibility, but also optimizing cost control and production planning, and ensuring welding quality and production efficiency.

[0005] In order to achieve the above-mentioned purpose, on the one hand, some embodiments of the present application provide a welding wire length measuring device, comprising: a signal emitting component, a signal receiving component and a processor. The signal emitting component is used to be installed on a wire feeding roller of a wire feeder, and outputs a to-be-measured signal with the rotation of the wire feeding roller. The signal receiving component is used to be installed on a body of the wire feeder, receives the to-be-measured signal, and generates a displacement sensing signal according to the to-be-measured signal. The processor is connected with the signal receiving component, and is configured to: acquire the displacement sensing signal, and determine the feeding size of the welding wire according to the displacement sensing signal and the diameter of the wire feeding roller.

[0006] In some embodiments of the present application, the signal emitting component comprises: a connecting part and a sensing part. The connecting part is used to be fixed on the wire feeding roller and rotates coaxially with the wire feeding roller. The sensing part is arranged on the side wall of the connecting part, and is used to generate the to-be-measured signal with the rotation of the connecting part.

[0007] For example, the sensing part comprises a sensing magnet. The to-be-measured signal is a magnetic field change signal.

[0008] In some embodiments of the present application, the signal receiving component comprises: a sensor. The sensor is arranged opposite to the signal emitting component, and is used to receive the to-be-measured signal and generate the displacement sensing signal according to the to-be-measured signal. Wherein, the displacement sensing signal is a pulse signal generated by the sensor when the signal emitting component approaches or moves away from the sensor.

[0009] In some embodiments of the present application, the signal receiving assembly further comprises a fixing structure. The fixing structure is fixedly connected to the sensor and the body of the wire feeder.

[0010] For example, the fixing structure comprises a mounting bracket, an adjusting portion and a fastening portion located at two ends of the mounting bracket. The mounting bracket extends along a direction perpendicular to the axis of the wire feeding roller. The adjusting portion is connected to the first end of the mounting bracket and the sensor, and is configured to adjust the distance between the sensor and the signal transmitting assembly. The fastening portion is arranged at the second end of the mounting bracket away from the first end, and is configured to be fixedly connected to the body of the wire feeder.

[0011] In some embodiments of the present application, the wire length measuring device further comprises a display. The display is connected to the signal transmitting assembly, the signal receiving assembly and the processor, and is configured to interact with the signal transmitting assembly, the signal receiving assembly and the processor in response to a user operation.

[0012] In some embodiments of the present application, the wire length measuring device further comprises a communication interface. The communication interface is connected to the processor, and is configured to communicate and exchange data with an external welding device and / or a production management system.

[0013] In another aspect, the present application also provides a wire feeder according to some embodiments. The wire feeder comprises a body, a wire feeding roller arranged on the body, and a wire length measuring device according to any of the above embodiments. The signal transmitting assembly is mounted on the wire feeding roller, and the signal receiving assembly is mounted on the body.

[0014] In some embodiments of the present application, the wire feeder further comprises a control system connected to the wire feeding roller. The processor is integrally integrated with the control system.

[0015] The embodiments of the present application can have / at least have the following advantages:

[0016] In the embodiments of the present application, after the signal transmitting assembly mounted on the wire feeding roller outputs the to-be-measured signal along with the rotation of the wire feeding roller, and the signal receiving assembly mounted on the body of the wire feeder receives the to-be-measured signal and generates the displacement sensing signal according to the to-be-measured signal, the processor can accurately determine the feeding size of the welding wire according to the displacement sensing signal and the diameter of the wire feeding roller, i.e., the feeding length of the welding wire can be accurately measured. Compared with the traditional method of estimating the welding wire consumption by using welding current, the embodiments of the present application avoid manual measurement and manual estimation, can reduce the risk of introducing human error, and can provide more accurate measurement data, thereby improving the calculation accuracy of production efficiency.

[0017] On this basis, the application embodiment can more effectively manage the inventory and use of welding wire by accurately measuring the feeding size of the welding wire, reduce the waste of welding wire, reduce the material cost, and improve the production efficiency. At the same time, the application embodiment facilitates the collection and analysis of welding wire length measurement data (i.e. welding wire use data) during the welding process, which can provide support for production management and quality control through accurate welding wire length measurement data, to help optimize production plans, further reduce production costs, and better control the welding wire filling amount during the welding process, thereby improving the welding quality.

[0018] In addition, the welding wire length measuring device provided by the application embodiment is also easy to install, has high adaptability, can be compatible with multiple models and multiple sizes of wire feeders, and can be conveniently installed on the wire feeder without the need for large-scale equipment modification. Moreover, the welding wire length measuring device provided by the application embodiment is also conducive to improving the intelligent level of the wire feeder and the welding equipment and / or production management system, so as to facilitate automatic production control.

[0019] In summary, the welding wire length measuring device provided by the application embodiment can accurately measure the feeding length of the welding wire, so as to accurately calculate the production benefit, thereby not only having high equipment compatibility and adaptability in different welding applications, but also being able to optimize cost control and production plans, and ensuring welding quality and production efficiency, and providing users with more accurate and convenient welding process monitoring and management tools.

[0020] The details of one or more embodiments of the application are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the application will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the application, and for those skilled in the art, other drawings can also be obtained from these drawings without creative labor.

[0022] Figure 1 A structural block diagram of a welding wire length measuring device provided in some embodiments;

[0023] Figure 2 A three-dimensional structural schematic diagram of a signal transmitting assembly and a signal receiving assembly in a welding wire length measuring device provided in some embodiments;

[0024] Figure 3 A front view of the signal transmitting assembly and the signal receiving assembly shown in the above figure; Figure 2

[0025] ​Figure 4 FIG. 1 is a perspective view of a signal transmitting assembly and a signal receiving assembly according to an embodiment of the present application; Figure 2 FIG. 2 is a left view of the signal transmitting assembly and the signal receiving assembly shown in FIG. 1;

[0026] Figure 5 FIG. 3 is a block diagram of another welding wire length measuring device provided in some embodiments.

[0027] BEST MODE FOR CARRYING OUT THE INVENTION

[0028] 1 - signal transmitting assembly, 11 - connecting portion, 12 - sensing portion, 13 - screw, 14 - nut, 2 - signal receiving assembly, 21 - sensor, 22 - fixing structure, 221 - mounting bracket, 222 - adjusting portion, 223 - fastening portion, 3 - processor, 4 - display. DETAILED DESCRIPTION

[0029] For the purposes of promoting an understanding of the principles of the application, reference will now be made to the embodiments illustrated in the drawings. It is expressly understood that the drawings are for illustrative purposes and should not be used in determining the scope of the application. In the drawings:

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0031] It will be understood that when an element or layer is referred to as being "on" or "connected to" another element or layer, it can be directly on or connected to the other element or layer or intervening elements or layers can be present. In addition, it will be understood that when a component is referred to as being "coupled" to another component, it can be directly coupled to the other component or intervening components can be present. Furthermore, spatially relative terms, such as "beneath", "below", "lower", "above", "upper", and the like, can be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the drawings. For example, if a device described herein is turned over in use, a component or feature that is higher in

[0032] As used herein, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Also, as used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0033] Referring to Figure 1 Some embodiments of the present application provide a welding wire length measuring device, comprising: a signal emitting component 1, a signal receiving component 2 and a processor 3. The signal emitting component 1 is configured to be installed on a wire feeding roller of a wire feeder, and output a to-be-measured signal with the rotation of the wire feeding roller. The signal receiving component 2 is configured to be installed on a body of the wire feeder, receive the to-be-measured signal, and generate a displacement sensing signal according to the to-be-measured signal. The processor 3 is connected with the signal receiving component 2, and is configured to: acquire the displacement sensing signal, and determine a feeding size of the welding wire according to the displacement sensing signal and a diameter of the wire feeding roller.

[0034] Optionally, the processor 3 is also connected with the signal emitting component 1. The processor 3 and the signal emitting component 1, the signal receiving component 2 can also interact with other signals, such as control signals of the signal emitting component 1 and the signal receiving component 2.

[0035] In some embodiments of the present application, please refer to Figures 2-4 It should be understood that the signal emitting component 1 comprises: a connecting part 11 and a sensing part 12. The connecting part 11 is configured to be fixed on the wire feeding roller and rotate coaxially with the wire feeding roller. The sensing part 12 is arranged on the side wall of the connecting part 11, and is configured to generate the to-be-measured signal with the rotation of the connecting part 11.

[0036] For example, the connecting part 11 has a cylindrical or sleeve structure, and the axis of the connecting part 11 coincides with the axis of the wire feeding roller.

[0037] For example, the connecting part 11 is provided with a screw rod 13 and a nut 14 on both sides along the axis of the connecting part 11, and the connecting part 11 can be fixed on the wire feeding roller through the screw rod 13 and the nut 13.

[0038] For example, the sensing part 12 includes but is not limited to a sensing magnet. Correspondingly, the to-be-measured signal generated by the sensing part 12 is a magnetic field change signal, that is, the sensing part 12 will generate a magnetic field change with the rotation of the wire feeding roller.

[0039] Optionally, the sensing magnet is a neodymium iron boron magnet or other magnet with strong magnetism, so as to ensure that a stable magnetic field signal can be generated when the wire feeding roller rotates.

[0040] Optionally, the inductive part 12 is provided in a plurality of numbers and is evenly distributed on the side wall of the connecting part 11. However, the arrangement position and the arrangement number of the inductive part 12 can ensure the detection range of the optimized magnetic field and has better stability.

[0041] In some embodiments of the present application, please refer to Figures 2-4 , the signal receiving assembly 2 comprises a sensor 21.

[0042] The sensor 21 is arranged opposite to the signal transmitting assembly 1, especially opposite to the inductive part 12 and within the detection range of the magnetic field generated by the inductive part 12. The sensor 21 is used to receive the to-be-detected signal and generate the displacement sensing signal according to the to-be-detected signal. The displacement sensing signal is a pulse signal generated by the sensor 21 when the signal transmitting assembly 1 approaches or moves away from the sensor 21. Correspondingly, the processor 3 can convert the aforementioned pulse signal into a count signal, such as the number of rotations of the wire feeding roller, after obtaining the aforementioned pulse signal, so as to determine the displacement distance of the welding wire, i.e. the feeding size of the welding wire, according to the count signal and the diameter of the wire feeding roller.

[0043] For example, the sensor 21 comprises a Hall effect sensor or a photoelectric sensor.

[0044] In the embodiments of the present application, the sensor 21 needs to have high sensitivity, high heat resistance and high wear resistance to ensure that it can accurately sense the position change of the inductive part 12 and can well adapt to the high temperature and harsh environment in the welding process.

[0045] In some embodiments of the present application, please refer to Figures 2-4 , the signal receiving assembly 2 further comprises a fixing structure 22. The fixing structure 22 is fixedly connected to the sensor 21 and the body of the wire feeder.

[0046] For example, the fixing structure 22 comprises a mounting bracket 221 and an adjusting part 222 and a fastening part 223 located at both ends of the mounting bracket 221. The mounting bracket 221 extends in a direction perpendicular to the axis of the wire feeding roller to provide a fixed support function for the sensor 21. The adjusting part 222 is connected to the first end of the mounting bracket 221 and the sensor 21 to adjust the distance between the sensor 21 and the signal transmitting assembly 1. The fastening part 223 is arranged at the second end of the mounting bracket 221 away from the first end to be fixedly connected to the body of the wire feeder.

[0047] Optionally, the mounting bracket 221 comprises, but is not limited to, a light and strong bracket such as an aluminum alloy bracket to reduce the weight of the welding wire length measuring device and improve its durability. In addition, the mounting bracket 221 can also be a space-adjustable bracket to facilitate the adaptation to different models and sizes of wire feeders.

[0048] Optionally, the adjusting part 222 and the fastening part 223 can be realized by using a lock nut and a bolt, so as to ensure the stability and reliability of the welding wire length measuring device on the wire feeder.

[0049] Optionally, the adjusting part 222 and the fastening part 223 can be made of a corrosion-resistant material, for example, stainless steel, so as to prolong the service life of the welding wire length measuring device.

[0050] In some embodiments of the present application, the processor 3 has data acquisition and data processing functions. For example, the processor 3 includes a high-speed data acquisition card and corresponding data processing software, and can capture and process the pulse signals output by the sensor 21 in real time.

[0051] Further, the processor 3 can also prestore an optimization algorithm to filter out noise interference, so as to improve the measurement accuracy of the welding wire length measuring device.

[0052] In some embodiments of the present application, referring to Figure 5 , the welding wire length measuring device further includes a display 4. The display 4 is connected with the signal transmitting assembly 1, the signal receiving assembly 2 and the processor 3, and is configured to interact with the signal transmitting assembly 1, the signal receiving assembly 2 and the processor 3 in response to user operation.

[0053] The type of the display 4 is not limited in the embodiments of the present application, and can be any display screen or display terminal having display and touch functions. In the embodiments of the present application, a user-friendly operation interface and a movable application program can be arranged in the display 4, so as to facilitate the user to monitor and adjust the parameter settings of each component in the welding wire length measuring device, and to obtain real-time feedback and historical records of relevant data, so as to help the user to analyze the welding wire usage and optimize the welding process.

[0054] In some embodiments of the present application, the welding wire length measuring device further includes a communication interface. The communication interface is connected with the processor 3, and is used to communicate with and exchange data with an external welding equipment and / or a production management system. The number of the communication interfaces and the corresponding communication protocols can be selected and set according to the requirements, and the embodiments of the present application are not limited in this regard.

[0055] Optionally, the communication interface is integrated on the shell of the processor 3 or the display 4.

[0056] In the embodiments of the present application, the signal emitting assembly 1 installed on the wire feeding roller outputs the to-be-measured signal with the rotation of the wire feeding roller, and the signal receiving assembly 2 installed on the wire feeder body receives the to-be-measured signal and generates a displacement sensing signal according to the to-be-measured signal. Then, the processor 3 can accurately determine the feeding size of the welding wire according to the displacement sensing signal and the diameter of the wire feeding roller, that is, the feeding length of the welding wire can be accurately measured. Compared with the conventional method of estimating the welding wire consumption by welding current, the embodiments of the present application avoid manual measurement and estimation, can reduce the risk of introducing human error, and provide more accurate measurement data, thereby improving the calculation accuracy of production efficiency.

[0057] On this basis, by accurately measuring the feeding size of the welding wire, the embodiments of the present application can more effectively manage the inventory and use of the welding wire, reduce the waste of the welding wire, reduce the material cost, and improve the production efficiency. At the same time, the embodiments of the present application facilitate the collection and analysis of the welding wire length measurement data (i.e., welding wire usage data) in the welding process, can provide support for production management and quality control through accurate welding wire length measurement data, help to optimize production plans, further reduce production costs, and better control the welding wire filling amount in the welding process, thereby improving the welding quality.

[0058] In addition, the welding wire length measurement device provided by the embodiments of the present application is also easy to install, has high adaptability, can be compatible with multiple models and multiple sizes of wire feeders, and can be conveniently installed on the wire feeder without the need for large-scale equipment modification. Moreover, the welding wire length measurement device provided by the embodiments of the present application is also conducive to improving the intelligent level of the wire feeder and welding equipment and / or production management system, so as to facilitate automatic production control.

[0059] In summary, the welding wire length measurement device provided by the embodiments of the present application can accurately measure the feeding length of the welding wire, so as to accurately calculate the production efficiency, thereby not only having high equipment compatibility and adaptability in different welding applications, but also being able to optimize cost control and production plans, and ensure welding quality and production efficiency, and providing users with more accurate and convenient welding process monitoring and management tools.

[0060] The present application also provides a wire feeder according to some embodiments, which comprises a body, a wire feeding roller arranged on the body, and a welding wire length measurement device as described in any of the above embodiments. The signal emitting assembly 1 is installed on the wire feeding roller, and the signal receiving assembly 2 is installed on the body. The wire feeder also has the technical advantages of the welding wire length measurement device, which will not be described in detail here.

[0061] In some embodiments of the present application, the wire feeder further comprises a control system connected with the wire feeding roller. The processor 3 is integrated with the control system, so as to easily realize the automatic control and data sharing of the wire feeder and the welding wire length measuring device.

[0062] In the description of the present application, the description of the terms "some embodiments", "some examples", "exemplarily" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiments or examples are contained in at least one embodiment or example of the present application. In the present application, the illustrative description of the above terms does not necessarily refer to the same embodiment or example.

[0063] The technical features of the above embodiments can be combined arbitrarily. In order to make the description simple, not all possible combinations of the technical features in the above embodiments are described, however, as long as the combinations of the technical features do not contradict, they should be considered as the scope of the present application.

[0064] The above embodiments only express several implementation manners of the present application, the description is more specific and detailed, but it should not be understood as the limitation of the scope of the utility model patent. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are all within the protection scope of the present application.

Claims

1. A welding wire length measuring device, characterized in that, a signal transmitting assembly is arranged on a wire feeding roller of a wire feeder, and outputs a to-be-measured signal as the wire feeding roller rotates; a signal receiving assembly is arranged on a body of the wire feeder, receives the to-be-measured signal, and generates a displacement sensing signal according to the to-be-measured signal; a processor is connected with the signal receiving assembly, and is configured to acquire the displacement sensing signal, and determine a feeding size of the welding wire according to the displacement sensing signal and a diameter of the wire feeding roller.

2. The welding wire length measuring device of claim 1, wherein, The signal transmitting assembly comprises: a connecting portion arranged on the wire feeding roller and coaxially rotating with the wire feeding roller; an inductive portion arranged on a side wall of the connecting portion, and used to generate the to-be-measured signal as the connecting portion rotates.

3. The welding wire length measuring device of claim 2, wherein, The inductive portion comprises an inductive magnet, and the to-be-measured signal is a magnetic field change signal.

4. The welding wire length measuring device of claim 1, wherein, The signal receiving assembly comprises: a sensor arranged opposite to the signal transmitting assembly, and used to receive the to-be-measured signal and generate the displacement sensing signal according to the to-be-measured signal; wherein the displacement sensing signal is a pulse signal generated by the sensor when the signal transmitting assembly approaches or moves away from the sensor.

5. The welding wire length measuring device of claim 4, wherein, The signal receiving assembly further comprises: a fixing structure fixedly connected with the sensor and the body of the wire feeder.

6. The welding wire length measuring device of claim 5, wherein, The fixing structure comprises a mounting bracket, and an adjusting portion and a fastening portion arranged at two ends of the mounting bracket; wherein, the mounting bracket extends along a direction perpendicular to an axis of the wire feeding roller; the adjusting portion is connected with the sensor and a first end of the mounting bracket, and is used to adjust a distance between the sensor and the signal transmitting assembly; the fastening portion is arranged at a second end of the mounting bracket away from the first end, and is used to fixedly connect with the body of the wire feeder.

7. The welding wire length measuring device of claim 1, wherein, Further comprising: a display connected with the signal transmitting assembly, the signal receiving assembly and the processor respectively, and configured to interact with the signal transmitting assembly, the signal receiving assembly and the processor in response to a user operation.

8. The welding wire length measuring device of any of claims 1-7, wherein, Further comprising: a communication interface connected with the processor, and used to externally connect with a welding device and / or a production management system to communicate and exchange data.

9. A wire feeder, comprising: Comprising: a body, and a wire feeding roller arranged on the body; wherein the wire feeder further comprises the welding wire length measuring device according to any one of claims 1-8; the signal transmitting assembly is arranged on the wire feeding roller, and the signal receiving assembly is arranged on the body.

10. The wire feeder of claim 9, wherein, Further comprising: a control system connected with the wire feeding roller; wherein the processor is integrally integrated with the control system.

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