WIRE FEED DEVICE WITH ADJUSTABLE STROKE

Description

[0001] The present invention relates generally to welding systems and, more particularly, to a wire feeder with an adjustable lift point according to the preamble of claim 1, see for example JP 4 657832 B2).BACKGROUND

[0002] MIG welding, formerly known as Gas Metal Arc Welding (GMAW), combines the techniques and advantages of TIG welding's inert gas shielding with a continuous, consumable wire electrode. An electrical arc is created between the continuous, consumable wire electrode and a workpiece. As such, the consumable wire functions as the electrode in the weld circuit as well as the source of filler metal. MIG welding is a relatively simple process that allows an operator to concentrate on arc control.

[0003] A wire feeder is operationally connected to the power source and is designed to deliver consumable wire to a weld. Often times, it is desirable that a MIG welding system, including the wire feeder, be portable to support various welding operations outside of a shop or plant setting. The system may undergo movement from multiple locations in any given day. Wire feeder systems may have great mass and have a large footprint, taking up a significant amount of space. To facilitate moving the system, wire feeders are often supplied with a lift point so they can be moved by lifting equipment, such as a crane, gantry, or lift. Prior lift points for wire feeder systems are fixed with respect to the wire feeder assembly and spool reel. Wire feeder systems with fixed lift points are often unbalanced and have orientations that change as the system is lifted.SUMMARY

[0004] According to the present invention, a wire feeder having an adjustable lift point is defined in claim 1, which includes inter alia a wire supply source configured to supply welding wire, a wire drive assembly configured to feed wire to a welding gun from the wire supply source, and a support base. The wire supply source and the wire drive assembly are supported by the base, and a lift member is connected to the support base and is selectively movable in at least one direction with respect to the support base to enable adjustment of the lift point of the wire feeder.

[0005] Further preferred embodiments of the present invention are defined in the appended claims.

[0006] In some examples, the lift member is selectively moveable in at least two directions with respect to the support base. In some examples, the lift member is configured to be selectively rotated about an axis to adjust the lift point. The wire feeder may include a latch assembly actuatable to selectively lock the lift member in positions with respect to the support base. In some examples, the wire feeder includes a latch assembly with a lever arm that is pivotable about a lever axis between a latched position and an unlatched position. A lift member is movable with respect to the support base to enable adjustment of the lift point when the lever is in the unlatched position, and the lift member is locked with respect to the support base when the lever is in the latched position.

[0007] In some examples, the latch assembly has a biasing member to bias the lever to the locked position. In some examples, the wire feeder includes a fastener, and a plate including a plurality of openings. The fastener is removably insertable into the openings to selectively lock the lift member in a plurality of positions with respect to the base.

[0008] In some examples, the wire drive assembly is positioned in front of the wire supply source on the support base. In some such examples, a longitudinal direction is defined between the wire drive assembly and the wire supply source, and the lift member is selectively movable in a direction transverse to the longitudinal direction to enable horizontal adjustment of the lift point of the wire feeder.

[0009] In some examples, the lift member is selectively moveable to a plurality of positions with respect to the support base, including a lift position in which the lift member is located above at least one of the wire drive assembly and the wire supply source with respect to the vertical direction, and a tow position in which the lift member is located at a forward end of the support base or a rear end of the support base to enable towing of the wire feeder with the lift member.

[0010] In some examples, the support base comprises a plate defining a support surface, the wire drive assembly and the wire supply source are positioned on the support surface, and the lift member is located at a front portion of the plate forward of the wire drive assembly when the lift member is in the tow position.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is an isometric view of an example a wire feeder having an adjustable lift point. FIG. 2 is an isometric view of the welding system of FIG. 1 with the lift point in a tow position. FIG. 3 is an isometric view of another example a wire feeder having an adjustable lift point. FIG. 4 is an isometric view of another example wire feeder having an adjustable lift point.

[0012] The figures are not necessarily to scale. Wherever appropriate, similar or identical reference numerals are used to refer to similar or identical components.DETAILED DESCRIPTION

[0013] For the purpose of promoting an understanding of the principles of the present invention and presenting its currently understood, best mode of operation, reference will be now made to the embodiments illustrated in the drawings and specific language will be used to describe the same.

[0014] As used herein, the word "exemplary" means "serving as an example, instance, or illustration." The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the term "embodiments" does not require that all disclosed embodiments include the discussed feature, advantage, or mode of operation.

[0015] As utilized herein the terms "circuits" and "circuitry" refer to physical electronic components (i.e. hardware) and any software and / or firmware ("code") which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As used herein, for example, a particular processor and memory may comprise a first "circuit" when executing a first set of one or more lines of code and may comprise a second "circuit" when executing a second set of one or more lines of code. As utilized herein, "and / or" means any one or more of the items in the list joined by "and / or". As an example, "x and / or y" means any element of the three-element 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 element of the seven-element 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 utilized herein, the term "exemplary" means serving as a non-limiting example, instance, or illustration. As utilized herein, the terms "e.g." and "for example" set off lists of one or more non-limiting examples, instances, or illustrations. As utilized herein, circuitry is "operable" to perform a function whenever the circuitry comprises the necessary hardware and code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or not enabled (e.g., by an operator-configurable setting, factory trim, etc.).

[0016] The present invention will be described with respect to a welding system with an adjustable lift point including a wire feeder of a MIG welding system.

[0017] Referring to FIGS. 1 and 2, a welding system 100 includes a wire feeder 102 with a drive assembly 104 and a wire supply source 106, and a support base 108. The drive assembly 104 of the wire feeder 102 includes rollers or gears (not shown) to advance consumable welding wire from the wire supply source 106 to a welding torch or gun. In the embodiment shown, the drive assembly 104 is protected by a housing 112. In other embodiments, additional components of the wire feeder may be positioned in a housing such as housing 112. For example, the wire supply source may be positioned in a housing with the drive assembly (e.g., a briefcase wire feeder).

[0018] Power is supplied to the wire feeder 102 by a welding power source 114 through a weld cable 116. The power source is designed to run in various modes, such as voltage-controlled, or current-controlled, and is further configured to power other welding systems and to provide auxiliary power to various accessories. Power source 114 is designed to condition raw power supplied from a utility line or engine driven power supply and output power usable by the welding process. The output of the power source 114 is generally controlled by a controller and associated operational circuitry that regulates the secondary or output side of the power conditioning components. A gas supply line 126 connects the wire feeder 102 to a gas source or cylinder 128 to provide shield gas for welding operations.

[0019] A welding gun or torch 118 connects to the wire feeder 102 via a wire guide line 120. The gun 118 is configured to supply consumable welding wire to a workpiece. Control signals are transmitted between the torch 118 and the wire feeder 102 via a control line 122. Torch 118 is equipped with a trigger 119 that, when depressed, causes a transceiver of a controller (not shown) in the housing 112 of the wire feeder 102 to transmit control signals to the power source 114 through weld cable 116.

[0020] The wire supply source 106 in the example of FIG. 1 includes a reel or a hub 130 that rotatably supports a spool 132 of welding wire (welding wire not shown). Wire is drawn from the spool 132 by the drive assembly 104. The spool 132 rotates to allow additional wire to be unwound from the spool as the wire is drawn through the drive assembly 104. While a spool of wire is depicted, other sources of wire may be utilized by wire feeder 102, for example, a free spool, a container or box with spooled wire, or any other desirable source of welding wire usable by a drive assembly.

[0021] The drive assembly 104 and wire supply source 106 are supported by a support base 108. The support base 108 rigidly connects the drive assembly and the wire supply source together to ensure proper orientation to perform a welding operation, and to allow the feeder to be transported. In the embodiment depicted, the drive assembly 104 and the wire supply source 106 are supported on a support plate 140 of the support base 108. The drive assembly and wire supply in the embodiment shown are mounted to the plate, for example, bolted to the plate, welded to the plate, or the like.

[0022] The welding system 100 further includes a lift member 142 connected to the support base 108 which facilitates the lifting and transportation of the wire feeder 102. The lift member 142 is a lift eye that is sized to receive the hook or other attachment structure of a crane, gantry, or other suitable lifting device (not shown). The hook or other attachment structure is connected to the lift member 142 and the lifting device is operated to lift and maneuver the welding system 100 from one location to another. For example, the system may be lifted from the bed of a truck and placed in a desirable location at a work site.

[0023] The lift member 142 includes a lift point 144, which is the point in dimensional space at which the welding system is lifted by, e.g., a lifting device. The location of the lift point 144 of welding system 100 is adjustable with respect to the support base 108, the drive assembly 104, and the wire supply source 106. In embodiments, the lift point of the welding system may be moved in one, two, or three dimensions to ensure the welding system is properly balanced when lifted. As a general matter, welding systems such as welding system 100 are typically oriented in a horizontal plane during operation, for example, while in the bed of a truck, on a stand, or the like, at a work site. When the system is lifted to transport or maneuver the system, the welding system is lifted at the lift point. If the lift point coincides with the center of gravity of the welding system, then the welding system is balanced and generally maintains the horizontal orientation when the system is lifted at the lift point. If not, the weld system may be unbalanced and tend to rotate or otherwise move to a different orientation. By adjusting the lift point, a desired balance and orientation may be achieved. Of course, while reference is made to the generally horizontal orientation, the lift point may be adjusted to achieve any desired orientation of the system when it is lifted, including any desired angle(s).

[0024] By providing an adjustable lift point, the desired balance or orientation may be achieved for multiple product configurations. For example, different models of wire feeders have various configuration, physical footprint, weights, weight distributions, center of gravity, and so forth, depending on the particular components thereof. With an adjustable lift point, a desired balance or orientation is achieved regardless of the specific type of configuration of components, including the specific center of gravity of such components and their position on a support structure to be lifted.

[0025] The adjustable lift point also accommodates shifts in the center of gravity of the system that may occur in day-to-day operation of a welding system. As an example, the center of gravity may change when a new wire spool is installed, as the wire supply source is depleted during operation, when sizeable cables are connected to the wire feeder, when equipment such as welding torches are placed on the wire feeder housing or support structure, and so forth. In these and other scenarios, the center of gravity may shift forward and aft (longitudinally), and / or to either side (laterally). Regardless of the reason for the resultant center of gravity, desired balance and orientation may be achieved by adjusting the lift point forward or aft (rearward or longitudinally), and / or to either side laterally (e.g., to coincide with the center of gravity). In another example, it may be desired to tow the welding system, or pull the system across a surface, such as in a generally horizontal direction. The lift point may be adjusted so that it is forward of, to the side, or to the rear of the wire feeder to facilitate such movement. An example of a tow position for welding system 100 is depicted in FIG. 2, where the lift point is forward of the drive assembly whereby the wire feeder may be pulled or towed across a surface. However, the welding system 100 may be configured to be towed from the reverse (e.g., backward) direction by configuring the lift point to the rear of the wire supply source 106. The example support base 108 may include, or be configured to attach, equipment (e.g., skids and / or wheels) to reduce the effort involved in towing the welding system 100 and / or reduce wear on the support base 108 due to towing.

[0026] In the example wire feeder 102, the lift member 142 is connected to the support plate 140 by a frame 146. The frame includes vertical frame members 148, 150 (e.g., beams) and a cross frame member 152 (e.g., crossbeam). The lift member 142 is secured to the frame member 152. The frame 146 is pivotable or rotatable with respect to the support frame about an axis 154. The frame 146 defines an opening between the frame members 148, 150, 152, enabling the frame 146 to pivot at least 180 degrees from a full vertical position depicted in FIG. 1, and a horizontal or tow position (one horizontal position depicted in FIG. 2), without obstruction by drive assembly 104, wire supply source 106, or other components of the welding system. By rotating the frame 146 with the lift member 142, the lift point 144 and the center of gravity of the welding system may be adjusted. The lift point 144 of welding system 100 is adjustable foreward and aft (longitudinally), as well as adjustable in the vertical direction.

[0027] Welding system 100 further includes a latch assembly 160 to lock the lift point 144 in one of plural, preselected positions. Latch assembly 160 includes a lever 162 with an arm 164, and a cog 166 with teeth 168. The example lift member 150 may be rotatably coupled to the cog 166 at the axis 154 (e.g., via a bolt and locknut, a threaded stud, etc.), or may be rotatably coupled to the base 108 such that the lift member 150 rotates with respect to the axis 154. The frame member 148 may be similarly coupled to a corresponding cog or plate, or to the support frame 108, with the same rotational axis 154.

[0028] Lever 162 is pivotable about axis 170 to move the latch assembly 160 between locked and unlocked positions. A biasing member, such as a torsion spring (not shown), biases lever 162 towards a locked position in which arm 164 of lever 162 cooperates within an opening between two adjacent teeth 168 of the cog 166. Latch assembly 160 may be actuated to an unlocked position by pivoting lever 162, causing arm 164 to move out of engagement with the cog 166. While unlocked, frame 146 may be rotated to a preselected position to adjust the lift point. The lever 162 may then be released. When released, lever 162 is biased to a locked position in which the arm 164 cooperates within an opening between adjacent teeth 168. Each opening between a pair of adjacent teeth 168 represents a different preselected position for the lift point. Adjustment allows for the welding system to be balanced for a lifting operation, and enables the lift point to be moved to positions that facilitate lifting, for example, as shown in FIG. 1, and to positions that facilitate towing, for example, as shown in FIG. 2.

[0029] Turning to FIG. 3, an example welding system 200 includes a wire feeder 202 with a drive assembly 204 and a wire supply source 206, and a support base 208. A support frame 246 is pivotably mounted to the support base 208, and supports a lift member 242. The welding system 200 includes a latch assembly 260 having a plate 266 with openings 268, and a fastener 264. The example plate 266 is rotatably connected to the support frame 246 at an axis 254 (e.g., via a bolt and locknut, a threaded stud, etc.), or may be rotatably coupled to the base 208 such that the support frame 246 rotates with respect to the axis 254. A similar plate may be rotatably connected to the support frame 246 and the support base 208 on an opposite side from the plate 266, such that both sides of the support frame 246 have the same rotational axis 254.

[0030] In the embodiment shown, the fastener 264 is a removable pin with a retaining detent (not shown) and / or locking pin. However, any suitable fastener may be used to implement the fastener, such as a bolt and locknut combination. The support frame 246 also includes an opening (not shown). The support frame 246 is pivotable to a plurality of positions in which the opening of the support frame 246 aligns with a selected opening 268 of the plate 266. When the openings are aligned, the fastener 264 is inserted to lock the support frame 246 in place. By selecting a desired position, the lift point of the welding system 200 and the center of gravity may be adjusted.

[0031] FIG. 4 depicts another example welding system 300 including a wire feeder 302 with a drive assembly 304 and a wire supply source 306, and a support base 308. A support frame 346 supports a lift member 342 with a lift point, and is removably mounted to the support base 308. The support frame 346 further includes a frame member 352 (e.g., beam) with a channel 353. The horizontal position of the lift member is adjustable within the channel 353 of the beam 352. The welding system 300 includes a latch assembly 360 and a latch assembly 370. Latch assembly 360 includes a plate 366 with openings 368, and a fastener 364. The latch assembly 360 includes a plurality of openings 369 on either side of the support base 308. With the fastener 364 removed, the support frame 346 is movable along the length of the support base 308 to adjust the lift point in the front / rear direction. The example support frame 346 is attached to the plate 366 (e.g., via welding, via one or more fasteners, etc.), and may be attached to a similar plate on an opposite side of the support base 308. The support frame 346 is locked in position by aligning an opening 368 of the plate 366 with an opening 369 of the support base 308, and inserting the fastener 364 through the aligned openings.

[0032] Latch assembly 370 includes a plurality of openings 378 in the frame member 352, a corresponding opening (not shown) in the lift member 342, and a fastener 374. The lift member 342 is adjustable in the horizontal direction when the fastener 374 is removed. The lift member 342 may be locked in place horizontally by aligning the opening (not shown) of the lift member 342 with a corresponding opening 378, and inserting the fastener 374 through the aligned openings. In the described manner, the latching mechanisms 360, 370 enable adjustment of the lift member in the forward / rearward (longitudinal) and horizontal (lateral) directions to adjust the lift point and the center of gravity of the welding system 300. In other embodiments, vertical adjustment is also implemented. For example, in embodiments, a plurality of openings are located in a first vertical frame member of the support frame, such as support frame 346, which may be aligned with corresponding openings with another vertical frame member, and locked in place with a bolt or pin. Any desired configuration to provide adjustment of the location of the lift point and / or center of gravity in one dimension, two dimensions, or three dimensions (x, y, z plane, and including rotational positions) may be implemented. As used herein, adjustment of the lift point with respect to the support base according to any of the foregoing examples may also be considered as an corresponding adjustment in the moment of the lifted welding system (e.g., the equipment attached to the support base and lifted via the lift point) with respect to the lift point.

[0033] As stated above, the present invention is also applicable with non-MIG welding systems such as TIG and stick welders.

[0034] While example support frames 146, 246, 346 for lift points 142, 242, 342 are disclosed and depicted, other structures or shapes may be used to implement the support frames. For example, instead of multiple pieces (e.g., frame members, beams, etc.) being assembled to create the support frame, one or more pieces may be curved, bent, molded, cast, and / or otherwise fabricated to reduce the number of joints present in the support frame. For example, the support frame may be fabricated as a single, generally U-shaped member, to which the lift point can be affixed and / or adjusted.

[0035] In some examples, instead of physically moving a lift member 142, 242, 342 and securing the lift member to different points on the support frames 146, 246, 346, in other examples multiple lift members are integral to the support frames 146, 246, 346, allowing for direct attachment of the lifting equipment to different integral lift members to change the lift point with respect to the center of gravity of the welding system.

[0036] The present invention has been described in terms of preferred embodiments, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible as long as they are falling under the scope of the present invention as defined in the appending claims.

Claims

1. A wire feeder (102) having an adjustable lift point, comprising: a wire supply source (106) configured to supply welding wire; a wire drive assembly (104) configured to feed wire to a welding gun from the wire supply source (106); a support base (108), the wire supply source (106) and the wire drive assembly (104) supported by the base (108); and the wire feeder being characterised by: a lift member (142) connected to the support base (108) , the lift member is a lift eye, which is sized to receive a hook or other attachment structure of a crane, gantry, or other suitable lifting device, and which is selectively movable in at least one direction with respect to the support base (108) to adjust a position of the lift eye with respect to the base (108) to enable thereby adjustment of the lift point of the wire feeder (102).

2. The wire feeder (102) of claim 1, wherein the lift member (142) is selectively moveable in at least two directions with respect to the support base (108).

3. The wire feeder (102) of claim 1, wherein the lift member (142) is configured to be selectively rotated about an axis to adjust the lift point.

4. The wire feeder (102) of claim 1, further comprising a latch assembly (160) actuatable to selectively lock the lift member (142) in positions with respect to the support base (108) and optionally wherein the latch assembly (160) further comprises a lever (162) arm (164), wherein: the lever arm (164) is pivotable about a lever axis between a latched position and an unlatched position; the lift member (142) is movable with respect to the support base (108) to enable adjustment of the lift point when the lever (162) is in the unlatched position; and the lift member (142) is locked with respect to the support base (108) when the lever (162) is in the latched position.

5. The wire feeder (102) of claim 4, further comprising a biasing member to bias the lever (162) to the locked position.

6. The wire feeder (102) of claim 1, further comprising: a fastener (264); and a plate (266) including a plurality of openings (268), wherein the fastener (264) is removably insertable into the openings (268) to selectively lock the lift member (142) in a plurality of positions with respect to the base (108).

7. The wire feeder (102) of claim 1, wherein the wire drive assembly (104) is positioned in front of the wire supply source (106) on the support base (108), in a longitudinal direction defined between the wire drive assembly (104) and the wire supply source (106), and the lift member (142) is selectively movable in a direction transverse to the longitudinal direction to enable horizontal adjustment of the lift point of the wire feeder (102).

8. The wire feeder (102) of claim 1, wherein the lift member (142) is selectively moveable to a plurality of positions with respect to the support base (108), including a lift position in which the lift member (142) is located above at least one of the wire drive assembly (104) and the wire supply source (106) with respect to the vertical direction, and a tow position in which the lift member (142) is located at a forward end of the support base (108) or a rear end of the support base (108) to enable towing of the wire feeder (102) with the lift member (142) and optionally wherein: the support base (108) comprises a plate (140) defining a support surface; the wire drive assembly (104) and the wire supply source (106) are positioned on the support surface (140); and the lift member (142) is located at a front portion of the plate (140) forward of the wire drive assembly (104) when the lift member (142) is in the tow position.