Wire straightening solution for bulk packaging

Abstract

To provide a wire straightening solution for bulk packaging.SOLUTION: The invention provides a configuration and method for straightening a wire as the wire is paid out from a bulk package. A bulk package hat is configured to be positioned over an opened bulk package containing a wire bent in a helix shape. A bearing assembly is attached inside the bulk package hat to a position where the wire exits the bulk package hat as the wire is paid out from the bulk package. A wire straightening device has a plurality of rollers and only one single plane of straightening, and is configured to apply a counter bend to the wire as the wire is paid out from the bulk package through the wire straightening device. The wire straightening device is operatively connected to the bearing assembly at an angle inside the bulk package hat. The bearing assembly and the single plane of straightening rotate while continually realigning with a current direction of the wire as the wire is paid out.SELECTED DRAWING: None

Description

[Technical Field]

[0001] CROSS-REFERENCE / INCORPORATION BY REFERENCE TO RELATED APPLICATIONS U.S. Patent No. 3,595,277, issued July 27, 1971, is incorporated herein by reference in its entirety. U.S. Patent No. 8,689,975, issued April 8, 2014, is incorporated herein by reference in its entirety.

[0002] Embodiments of the present invention relate to straightening wire, and more particularly, to straightening wire (e.g., consumable welding wire) when the wire is bent (e.g., spirally bent) within a bulk package as the wire is unwound from the bulk package. [Background technology]

[0003] Wires in bulk packaging are bent, for example, into a spiral, by the nature of the packaging process. To straighten the spiral, the wire is typically passed through two wire straighteners positioned at 90 degrees to each other to provide straightening in two planes. However, the use of wire straighteners creates drag on the wire, which increases the generation of harmful chips in the wire conduit and wear on the wire feeding system. It is desirable to reduce the drag on the wire by other means. Summary of the Invention [Means for solving the problem]

[0004] An embodiment of the present invention relates to an assembly and method for straightening a wire (e.g., a consumable welding wire) as it is paid out from a bulk package. A bulk package hat is configured to be positioned over a bulk package containing a helically bent wire. A bearing assembly is mounted inside the bulk package hat at a location where the wire exits the bulk package hat as it is paid out from the bulk package. A wire straightening device has a plurality of rollers and only one single straightening surface. The wire straightening device is configured to apply a counterbend to the wire on only one single straightening surface as the wire is paid out from the bulk package through the wire straightening device. The wire straightening device is operably connected at an angle to the bearing assembly inside the bulk package hat. The bearing assembly is configured to rotate in response to the wire being paid out from the bulk package through the wire straightening device. The wire straightening device remains at that angle so that the single straightening surface remains substantially realigned with the current direction toward the portion of the wire currently being paid out from the bulk package as the current direction changes.

[0005] In one embodiment, a wire straightening arrangement is provided for straightening a wire as it is unwound from a bulk package. The arrangement includes a bulk package hat configured to be positioned over an open bulk package containing a helically bent wire. A bearing assembly is mounted inside the bulk package hat at a location where the wire exits the bulk package hat as it is unwound from the bulk package. The arrangement also includes a wire straightening device having a plurality of rollers and only one single straightening surface. The wire straightening device is configured to apply a counterbend to the wire on only one single straightening surface as the wire is unwound from the bulk package through the wire straightening device. The wire straightening device is operably connected to the bearing assembly at an angle inside the bulk package hat. Rotation of the bearing assembly is caused by the wire being unwound from the bulk package through the wire straightening device. The bearing assembly is configured to rotate in response to the wire being unwound from the bulk package through the wire straightening device, while maintaining the angle of the wire straightening device so that the single straightening surface remains substantially realigned with the current direction toward the portion of the wire currently being unwound from the bulk package as the current direction changes. The single straightening surface rotates with the wire in response to the wire being unwound from the bulk package, allowing the spiral to be straightened by the wire straightening device. In one embodiment, the wire straightening device has a longitudinal axis extending therethrough. The bearing assembly is aligned along a vertical axis of the configuration, and an angle is formed between the vertical axis and the longitudinal axis. According to various embodiments, the angle between the vertical axis and the longitudinal axis can be, for example, 5 to 30 degrees, 1 to 10 degrees, or 15 to 45 degrees. According to various embodiments, the number of rollers in the wire straightening device can be, for example, three rollers, five rollers, or seven rollers.

[0006] In one embodiment, a method for straightening a wire as it is unwound from a bulk package is provided. The method includes positioning a bulk package hat over an open bulk package containing a helically bent wire and mounting a bearing assembly inside the bulk package hat at a position where the wire exits the bulk package hat as it is unwound from the bulk package. The method also includes operably connecting a wire straightening device having only one single straightening surface to the bearing assembly at an angle inside the bulk package hat. The method further includes feeding a distal portion of the wire through the wire straightening device as it is unwound from the bulk package to impart a counterbend to the wire at the one single straightening surface as it is unwound from the bulk package. The method also includes unwinding the wire and rotating the bearing assembly in response to the wire being unwound from the bulk package through the wire straightening device while maintaining the wire straightening device at an angle such that the single straightening surface remains substantially realigned with the current direction toward the portion of the wire currently being unwound from the bulk package as the current direction changes. In one embodiment, the method includes, as part of mounting, aligning the bearing assembly along a vertical axis of the configuration, and, as part of connecting, forming an angle between the vertical axis and a longitudinal axis of the wire straightening device. Rotation of the bearing assembly is effected by unwinding the wire from the bulk package through the wire straightening device. The method further includes rotating one single straightening plane with the wire depending on the wire being unwound from the bulk package, allowing the helix to be straightened by the wire straightening device. According to various embodiments, the method may include setting the angle between the vertical axis and the longitudinal axis to, for example, 5 to 30 degrees, 1 to 10 degrees, or 15 to 45 degrees. According to various embodiments, as part of feeding the wire, a distal portion of the wire is guided through three, five, or seven rollers of the wire straightening device.

[0007] Numerous aspects of the general inventive concept will become readily apparent from the following detailed description of exemplary embodiments, from the claims and from the accompanying drawings.

[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the present disclosure. It will be appreciated that the boundaries of elements depicted in the figures (e.g., boxes, groups of boxes, or other shapes) represent one embodiment of the boundaries. In some embodiments, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external component, and vice versa. Additionally, elements may not be drawn to scale. [Brief explanation of the drawings]

[0009] [Figure 1] 1 illustrates a schematic diagram of one embodiment of a wire straightening arrangement for straightening a wire as it is unwound from a bulk package. [Figure 2] 1 illustrates one embodiment of an opened bulk package. [Figure 3] 1 illustrates one embodiment of a wire straightening arrangement installed above a bulk package containing helically bent consumable welding wire. [Figure 4] 4 illustrates the embodiment of FIG. 3 showing the straightening plane through the wire straightening device in a wire straightening configuration. [Figure 5] 1 illustrates a flow chart of one embodiment of a method for straightening a wire as it is unwound from a bulk package. DETAILED DESCRIPTION OF THE INVENTION

[0010] Embodiments of the present invention relate to an assembly and method for straightening a wire (e.g., consumable welding wire) (i.e., removing a bent shape, such as a spiral, from the wire) as the wire is unwound from a bulk package (e.g., a bulk package having a cardboard structure). A bulk package hat is configured to be positioned over an open bulk package containing a bent wire, e.g., a spiral (although other shapes are possible). A bearing assembly is mounted inside the bulk package hat at a position where the wire exits the bulk package hat as it is unwound from the bulk package. The wire straightening device has multiple rollers and only one single straightening surface and is configured to apply a counterbend to the wire as it is unwound from the bulk package through the wire straightening device. The wire straightening device is operably connected at an angle to a bearing assembly inside the bulk package hat. The bearing assembly rotates in response to the wire being unwound from the bulk package through the wire straightening device. That is, rotation of the bearing assembly is effected by the wire being unwound from the bulk package through the wire straightening device, while the wire straightening device is kept at an angle such that the single straightening plane remains substantially realigned with the current direction toward the portion of the wire currently being unwound from the bulk package as the current direction changes.

[0011] The examples and figures herein are merely illustrative and are not meant to limit the invention. The invention is limited only by the scope and spirit of the claims. Reference is now made to the drawings, which are shown for purposes of illustrating exemplary embodiments of the invention only and are not intended to limit the same. FIG. 1 illustrates a schematic diagram of one embodiment of a wire straightening arrangement 100 for straightening wire as it is unwound from the bulk package. FIG. 2 illustrates one embodiment of an open bulk package 105 (i.e., a bulk package with the lid or cover removed) containing, for example, a coiled consumable welding wire 107. FIG. 3 illustrates one embodiment of a wire straightening arrangement 100 positioned above a bulk package 105 containing a helically wound consumable welding wire 107. FIG. 4 illustrates the embodiment of FIG. 3, showing a straightening surface 137 penetrating the wire straightening device 130 of the wire straightening arrangement 100.

[0012] The wire straightening arrangement 100 includes a bulk package hat 110 configured to be positioned over an open bulk package 105 (see, e.g., FIGS. 2, 3, and 4) containing a helically bent coiled wire 107 (see, e.g., FIGS. 2 and 4). That is, the wire 107 is stored in the bulk package 105 by coiling the wire 107 within the bulk package 105 so that the wire 107 forms a spiral. According to one embodiment, the bulk package hat 110 is somewhat conical in shape and made of a transparent plastic material. According to other embodiments, other types of hats (having other shapes and made of other materials) are possible as well. The wire straightening arrangement 100 also includes a bearing assembly 120 mounted within the bulk package hat 110 at a location 122 through which the wire 107 exits the bulk package hat 110 as the wire 107 unwinds from the bulk package 105 during operation. Paying out of wire 107 may be facilitated by a wire feeding device (not shown) and / or a welding gun (not shown), as is well known in the art.

[0013] The wire straightening configuration 100 further includes a wire straightening device 130 having a plurality of rollers 135 (e.g., three, five, or seven rollers) and only one single straightening surface 137 (see, e.g., FIG. 4 ). The wire straightening device 130 is configured to apply a counterbend to the wire 107 (via the rollers 135) at only one single straightening surface 137 (see, e.g., FIG. 4 ) as the wire 107 is unwound from the bulk package 105 through the wire straightening device 130. That is, the rollers 135 apply a counterbend force to the wire 107. Depending on the wire 107 being unwound from the bulk package 105, the one single straightening surface 137 rotates with the wire 107, allowing the spiral to be straightened by the wire straightening device 130. Generally, in operation, as the wire 107 is unwound, it is pulled out of the bulk package 105 through the wire straightening device 130, through the bearing assembly 120 and through the top of the bulk package hat 110.

[0014] The wire straightening device 130 is operably connected to the bearing assembly 120 in the bulk package hat 110 at an angle α (e.g., via a bracket 143 in one embodiment). According to one embodiment, as shown in FIG. 1 , the angle α is the angle between a central vertical axis 125 through the configuration 100 and a longitudinal axis 140 of the wire straightening device 130. The bracket 143 may be made of, for example, a metal, plastic, and / or ceramic material. Other types of materials are possible as well. According to other embodiments, means for connecting the wire straightening device 130 to the bearing assembly 120 other than the bracket 143 (e.g., bolts, screws, straps, magnets) are also possible. The bearing assembly 120 is configured to rotate about the vertical axis 125 (e.g., in a rotational direction 150) in response to the wire 107 being unwound from the bulk package 105 through the wire straightening device 130. That is, due in part to the manner in which the wire 107 is stored in the bulk package 105 in a spiral fashion, the movement of the wire 107 as it moves through the arrangement 100 as it is unwound results in a rotation.

[0015] The wire straightening device 130 is maintained at angle α so that the single straightening plane 137 (see, e.g., FIG. 4 ) remains substantially realigned with the current direction toward the portion of the wire 107 currently unwound from the bulk package 105 as the current direction changes due to rotation. That is, because the wire straightening device 130 is connected to the bearing assembly 120 at angle α, when the bearing assembly 120 rotates, the wire straightening device 130 also rotates. In some embodiments, angle α is between 5 degrees and 30 degrees. In other embodiments, angle α is between 1 degree and 10 degrees. In yet other embodiments, angle α is between 15 degrees and 45 degrees. According to one embodiment, the value of angle α can be selected based on, for example, the diameter or width of the bulk package 105. That is, the further the stored wire 107 is from the vertical axis 125, the larger the value of angle α can be set. According to one embodiment, angle α is adjustable via an adjustable joint (not shown) on the bracket 143.

[0016] According to one embodiment, the wire straightening device 130 is configured to rotate about its longitudinal axis 140 to a more suitable position during setup prior to operation. This places the single straightening surface 137 in a more suitable position. For example, a keying arrangement (not shown) can be used to loosen the wire straightening device 130 so that it can rotate about its longitudinal axis 140. Once the more suitable position is reached through rotation, the keying arrangement can be used to retighten the wire straightening device 130 so that it remains fixed in the more suitable rotated position relative to its longitudinal axis 140. According to one embodiment, the keying arrangement can include, for example, an L-shaped wrench and a screw. In theory, rotating the wire straightening device 130 (and the single straightening surface 137) to a more suitable position will ensure that most (if not all) of the helix is ​​removed from the wire during operation. The more preferred rotational position may be different for different embodiments of the wire straightening arrangement 100 and bulk package 105 depending, for example, on the angle α and / or the size of the bulk package 105 .

[0017] 5 illustrates a flowchart of one embodiment of a method 500 for straightening a wire as it is unwound from the bulk package. At block 510 of method 500, a bulk package hat is positioned over an open bulk package containing a helically bent wire. At block 520, a bearing assembly is mounted inside the bulk package hat at a location where the wire will exit the bulk package hat as it is unwound from the bulk package. The bearing assembly, according to one embodiment, is aligned along a vertical axis of the configuration as part of mounting the bearing assembly.

[0018] At block 530, a wire straightening device is operably connected to a bearing assembly within the bulk package hat at an angle, the wire straightening device having only one single straightening plane. According to one embodiment, as part of connecting the wire straightening device, an angle is formed between a vertical axis and a longitudinal axis of the wire straightening device. As part of connecting the wire straightening device to the bearing assembly, in some embodiments, the value of angle α is set between 5 degrees and 30 degrees. In other embodiments, the value of angle α is set between 1 degree and 10 degrees. In yet other embodiments, the value of angle α is set between 15 degrees and 45 degrees.

[0019] At block 540, as the wire is unwound from the bulk package through the wire straightening device, a tip portion of the wire is fed through the wire straightening device to impart a backbend to the wire in one single straightening plane. Rotation of the bearing assembly is effected by unwounding the wire from the bulk package through the wire straightening device. According to one embodiment, as part of feeding the wire, the tip portion of the wire is guided through rollers (e.g., three, five, or seven rollers) of the wire straightening device. The rollers impart a backbend force to the wire.

[0020] In block 550, the wire is paid out from the bulk package through a wire straightening device, and the bearing assembly rotates in response to the wire being paid out from the bulk package through the wire straightening device while holding the wire straightening device at an angle such that the single straightening surface remains substantially realigned with the current direction toward the portion of the wire currently being paid out from the bulk package as the current direction changes. That is, the single straightening surface of the wire straightening device rotates with the wire in response to the wire being paid out from the bulk package, allowing the helix to be straightened (removed) by the wire straightening device.

[0021] While the disclosed embodiments have been illustrated and described in considerable detail, it is not intended to constrain, or in any way limit, the scope of the appended claims to such details. For the purpose of describing various aspects of the subject matter, it is, of course, impossible to describe every conceivable combination of components or methodologies. Accordingly, the present disclosure is not limited to the specific details, nor is it limited to the illustrative examples shown and described. As such, the present disclosure is intended to embrace alterations, modifications, and variations that are within the scope of the appended claims, which satisfy the statutory subject matter requirements of 35 U.S.C. § 101. The specific embodiments described above are provided by way of example. From the present disclosure given, those skilled in the art will not only understand the general inventive concept and its attendant advantages, but will also find apparent various changes and modifications to the disclosed structures and methods. It is, therefore, sought to embrace all such changes and modifications as fall within the spirit and scope of the general inventive concept as defined by the appended claims and equivalents thereof. [Explanation of symbols]

[0022] 100 wire straightening configuration 105 Bulk Package 107 Consumable welding wire 110 Bulk Package Hat 120 Bearing Assembly 122 positions 125 Vertical axis 130 Wire Straightening Device 135 Laura 137 Linearization surface 140 Longitudinal Axis 143 Bracket 150 Rotation direction 500 ways 510, 520, 530, 540, 550 blocks α angle

Claims

1. a wire straightening arrangement for straightening the wire as it is unwound from the bulk package, the arrangement comprising: a bulk package hat configured to be positioned over the open bulk package containing the helically wound wire; a bearing assembly mounted inside the bulk package hat at a position where the wire exits the bulk package hat when the wire is unwound from the bulk package; a wire straightening device having a plurality of rollers and only one single straightening surface, the wire straightening device being configured to apply a reverse bend to the wire at the only single straightening surface as the wire is unwound from the bulk package through the wire straightening device; the wire straightening device is operably connected to the bearing assembly at an angle within the bulk package hat; the bearing assembly is configured to rotate in response to the wire being unwound from the bulk package through the wire straightening device while maintaining the wire straightening device at the angle such that the single straightening surface remains substantially realigned with the current direction toward the portion of the wire currently being unwound from the bulk package as the current direction changes. Wire straightening configuration.

2. 2. The wire straightening arrangement of claim 1, wherein the wire straightening device has a longitudinal axis therethrough, the bearing assembly is aligned along a vertical axis of the arrangement, and the angle is formed between the vertical axis and the longitudinal axis.

3. The wire straightening arrangement of claim 1 , wherein the rotation of the bearing assembly is caused by the wire being unwound from the bulk package through the wire straightening device.

4. 2. The wire straightening arrangement of claim 1, wherein the only single straightening surface rotates with the wire as the wire is unwound from the bulk package, allowing the spiral to be straightened by the wire straightening device.

5. The wire straightening arrangement of claim 1 , wherein the angle is between 5 degrees and 30 degrees.

6. The wire straightening arrangement of claim 1 , wherein the angle is between 1 degree and 10 degrees.

7. The wire straightening arrangement of claim 1 , wherein the angle is between 15 degrees and 45 degrees.

8. The wire straightening arrangement of claim 1 , wherein the plurality of rollers includes three rollers.

9. The wire straightening arrangement of claim 1 , wherein the plurality of rollers comprises five rollers.

10. The wire straightening arrangement of claim 1 , wherein the plurality of rollers includes seven rollers.

11. 1. A method for straightening a wire as it is unwound from a bulk package, comprising: positioning a bulk package hat over the opened bulk package containing the helically wound wire; mounting a bearing assembly inside the bulk package hat at a location where the wire exits the bulk package hat as the wire is paid out from the bulk package; operatively connecting a wire straightening device having only one single straightening surface to the bearing assembly at an angle within the bulk package hat; feeding a distal portion of the wire through the wire straightening device to apply a reverse bend to the wire in the only single straightening plane as the wire is unwound from the bulk package through the wire straightening device; paying out the wire and rotating the bearing assembly in response to the wire being paid out from the bulk package through the wire straightening device while maintaining the wire straightening device at the angle such that the only single straightening plane continues to substantially realign with the current direction toward the portion of the wire currently being paid out from the bulk package as the current direction changes. method.

12. 12. The method of claim 11, further comprising aligning the bearing assembly along a vertical axis of the arrangement as part of the mounting, and forming the angle between the vertical axis and a longitudinal axis of the wire straightening device as part of the connecting.

13. The method of claim 11 , further comprising: paying out the wire from the bulk package through the wire straightening device, thereby causing rotation of the bearing assembly.

14. 12. The method of claim 11, further comprising: the only one single straightening surface rotating with the wire in response to the wire being unwound from the bulk package, allowing the spiral to be straightened by the wire straightening device.

15. The method of claim 11 further comprising, as part of said connecting, setting said angle between 5 degrees and 30 degrees.

16. The method of claim 11 further comprising, as part of said connecting, setting said angle between 1 degree and 10 degrees.

17. The method of claim 11 further comprising, as part of said connecting, setting said angle between 15 degrees and 45 degrees.

18. The method of claim 11 , further comprising, as part of said feeding, directing said tip portion of said wire through three rollers of said wire straightening device.

19. The method of claim 11 further comprising, as part of said feeding, directing said tip portion of said wire through five rollers of said wire straightening device.

20. 12. The method of claim 11, further comprising, as part of said feeding, directing said tip portion of said wire through seven rollers of said wire straightening device.

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