WIRE FEEDING SYSTEM FOR A WELDING APPARATUS, WELDING APPARATUS AND METHOD FOR FEEDING WIRE TO A WELDING APPARATUS

Abstract

The invention provides a wire feeding system (100), a method for controlling the wire feed of a welding apparatus (1000), and a welding apparatus (1000). The wire feeding system (100) comprises at least: a welding wire storage device (110), which is designed such that a variable quantity of welding wire (42) currently disposed therein acts as an adjustable welding wire reserve; a welding wire push motor (121), by which the welding wire (42) can be conveyed to the welding wire storage device (100); and a welding wire pull motor (129), by which the welding wire (42) can be conveyed from the welding wire storage device (100).and a control device (130), which is configured to execute a wire feed program comprising at least two types of wire feed phases, each with at least different average wire feed speeds (Vd) of the welding wire drive motor (129), and wherein the control device (130) is also designed to adjust the welding wire reserve in a wire feed phase (P1, P3) of a first type of wire feed phase (T1) in preparation for a successive wire feed phase (P2, P4) of a second type of wire feed phase (T2). (Fig. 1) (See Figure 1).;

Description

[0001] title

[0002] Wire feed system for a welding machine, welding machine, and method for feeding a welding wire for a welding machine

[0003] Field of invention

[0004] The invention relates to a wire feed system for a welding machine, a welding machine with a wire feed system, and a method for feeding a welding wire for a welding machine.

[0005] Technical background

[0006] In welding processes using a consumable wire electrode, a welding wire is fed to a welding torch by a wire feed system. The faster the welding wire melts at the welding torch, the faster it must be re-fed. Therefore, during welding processes with a high melt rate, the typical average wire feed speed will be higher than in welding processes with a low melt rate.

[0007] Modern, highly developed welding processes use complex characteristic curves for welding parameters (voltage, current, wire feed speed) to produce optimal welding results. Sometimes, different types of welding phases are combined, for example, alternated, with each welding phase corresponding to a wire feed phase type that specifies or sets a suitable instantaneous wire feed speed for that particular welding phase type. Apart from their respective average (or mean) wire feed speeds, the wire feed phase types can also differ in their dynamics, i.e., in how frequently changes in wire feed speed must occur, or what accelerations or decelerations of the wire feed speed are required.

[0008] Due to various factors (e.g., the inertia of the wire feed system and the welding wire), typical welding wire push motors, which are usually located in or near the welding power source, cannot operate as dynamically as required at the welding torch. For this purpose, a welding wire pull motor is typically provided at the welding torch, which precisely sets the desired wire feed speed for the welding process.

[0009] It is often desirable to decouple the unwinding process of the welding wire, for example from a spool or drum, from the dynamic processes at the welding torch. However, the wire feed system also has the task, among others, of ensuring that enough welding wire is always available at the welding torch.

[0010] A known solution is to provide a so-called welding wire buffer, i.e., a reservoir of welding wire from which a highly dynamic welding process can draw in case the welding wire push motor cannot supply the welding wire itself at the required speed in time. Thus, the unwinding speed (or: initial speed, or: unwinding wire feed speed) of the welding wire at the welding wire push motor can differ from the instantaneous speed, but also from P60040-WG 29.09.2025

[0011] 3 differ in the average wire feed speed on the welding wire pull motor.

[0012] For example, Austrian patent AT 413 661 B describes a buffer device for a welding wire.

[0013] Another welding wire storage device is described in EP 1 708 842 Al. This comprises an angled housing along the path of the welding wire, wherein a welding wire buffer with a different radius of the welding wire arranged in the housing is formed in the housing.

[0014] To avoid complicating the welding process and handling the welding machine, a welding wire storage device should be designed with the smallest possible dimensions. For example, the outer contour of the welding machine plays a significant role in robotic applications, as it must be considered when guiding and controlling the robot. Large welding wire storage devices can create undesirable obstructions. At the same time, the maximum possible welding wire buffer is limited by the dimensions of the welding wire storage device.

[0015] Summary of the invention

[0016] Therefore, in light of the foregoing, it is an object of the present invention to provide a further improved wire feed system with a welding wire buffer, as well as an improved welding machine and an improved method for feeding a welding wire for a welding machine. At the same time, efforts are made to design the wire feed system to be as small and versatile as possible.

[0017] The invention thus provides, according to a first aspect, a wire feed system for a welding machine, comprising at least: a welding wire storage device, which is designed such that a variable quantity of welding wire currently arranged therein, passing through the welding wire storage device, acts as an adjustable welding wire buffer; a welding wire push motor, by means of which the welding wire can be conveyed towards the welding wire storage device; a welding wire pull motor, by means of which the welding wire can be conveyed away from the welding wire storage device (in particular towards a contact tube of a welding torch of a welding machine);and a control device configured to execute a wire feed program, wherein the wire feed program comprises at least two wire feed phase types, each with at least different mean wire feed speeds of the welding wire pull motor, and wherein the control device is also configured to set the welding wire buffer, at least by appropriately controlling the welding wire push motor, in a wire feed phase of a first wire feed phase type in preparation for a subsequent wire feed phase of a second wire feed phase type.

[0018] A welding wire buffer is understood to be, in particular, a length of welding wire that can be consumed at a welding torch of the welding machine or at least fed towards the workpiece without the welding wire becoming fully taut and thus stopping the wire feed. The welding wire buffer therefore enables highly dynamic control of the welding wire at the welding torch without the welding wire push motor necessarily needing to be equally dynamic.

[0019] The welding wire storage device can, for example, be designed as described in EP 1 708 842 Al, which is hereby incorporated in its entirety into the present description by reference. A welding wire storage device designed in this way can also be called an "angle storage device". However, other shapes are also conceivable, for example, S-shaped welding wire storage devices (i.e., with an S-shaped path of the welding wire within them), shapes with three or more changes in the curvature of the welding wire within them, or the like.

[0020] Preparatory adjustment of the welding wire buffer means that the welding wire buffer present in the wire feed phase of the first wire feed phase type is already changed within this wire feed phase in order to provide a suitable welding wire buffer for the respective subsequent wire feed phase.

[0021] In particular, the unwinding speed Va, at which the welding wire push motor feeds the welding wire into the wire feed system, can be set differently from the average wire feed speed Vd of the welding wire at the contact tube of the welding torch. The welding wire buffer increases when the unwinding speed Va exceeds the average wire feed speed Vd (Va > Vd) and decreases in the opposite case (Vd > Va). P60040-WG 29.09.2025

[0022] 6. The average wire feed rate Vd typically corresponds to the melting rate of the welding wire, i.e., the length of welding wire that is melted off per unit of time and therefore must be replenished by the average wire feed rate.

[0023] According to the invention, the welding wire buffer currently available can thus be optimally adjusted to the welding task to be performed, or more precisely, to the wire feed phase type of the pending wire feed phase. In the prior art, if the welding wire buffer is set too small, insufficient welding wire is supplied during a highly dynamic positive wire feed. Conversely, if the welding wire buffer is set too large, during a highly dynamic negative wire feed, the returned welding wire cannot be completely absorbed into the welding wire storage device. Both of these situations can lead to problems or an undesirable interruption of the welding process.

[0024] The aforementioned control unit can be implemented as any device capable of performing calculations, and in particular, of executing software, an application, or an algorithm. The control unit can, for example, comprise at least one processor unit, such as a central processing unit (CPU) and / or a graphics processing unit (GPU) and / or a field-programmable logic gate (FPGA) and / or an application-specific integrated circuit (ASIC) and / or a combination thereof. The control unit can also comprise a working memory operationally coupled to the at least one processor unit, as well as non-volatile memory connected to the at least one processor unit.

[0025] 7

[0026] The control unit is operationally coupled to the processor unit and the main memory. The control unit can be implemented wholly or entirely in a local device, such as a wire feeder, a welding power source and / or a welding machine, and / or wholly or entirely in a remote system, such as a remotely located server and / or a cloud computing platform.

[0027] According to some preferred embodiments, variants, or refinements of embodiments, the first wire feed phase type has a first average wire feed speed Vdl of the welding wire pull motor. The control device is advantageously configured to increase the welding wire buffer from a first welding wire buffer level to a second welding wire buffer level in each wire feed phase of the first wire feed phase type if the second wire feed phase type has a second average wire feed speed Vd2 of the welding wire pull motor, which is higher than the first average wire feed speed Vdl (i.e., Vd2 > Vdl).

[0028] Thus, for wire feed phases (or, in other words, for wire feed phase types) with higher average wire feed speed, where typically higher wire feed instantaneous speeds of the welding wire pull motor are also present (since the average wire feed speed is formed as the average of the wire feed instantaneous speeds), a larger welding wire buffer level can regularly be provided.

[0029] According to some preferred design forms, variants or

[0030] For refinements of the design, the control unit is configured to adjust the welding wire buffer to the first welding wire buffer level PI at the latest at the beginning of each wire feed phase of the first wire feed phase type, and to the second welding wire buffer level at the latest at the beginning of each wire feed phase of the second wire feed phase type. This means that the wire feed system is controlled in such a way that the corresponding welding wire buffer level is present at the beginning of each wire feed phase type. Thus, the wire feed system is always optimally adjusted for the upcoming wire feed phase.

[0031] According to some preferred embodiments, variants or refinements of embodiments, the control device is configured to reduce the welding wire buffer from the second welding wire buffer level to the first welding wire buffer level in each wire feed phase of the second wire feed phase type, if each wire feed phase of the second wire feed phase type is followed by a wire feed phase of the first wire feed phase type.

[0032] The control device can also be configured to reduce the welding wire buffer from the second welding wire buffer level to a third welding wire buffer level, which is lower than the second welding wire buffer level, in each wire feed phase of the second wire feed phase type, if each wire feed phase of the second wire feed phase type is followed by a wire feed phase of a third wire feed phase type, which has a third average wire feed speed VdS of the welding wire pull motor that is lower than the second average wire feed speed Vd2 (i.e., Vd3). <Vd2 ) . P60040-WG 29 . 09 . 2025

[0033] 9

[0034] According to some preferred embodiments, variants, or refinements of embodiments, the absolute difference between the mean wire feed speed of the welding wire pull motor of the first wire feed phase type and the mean wire feed speed of the welding wire pull motor of the second wire feed phase type is at least 0.1 m / min, preferably 1 m / min, particularly at least 5 m / min, and most preferably at least 7 m / min. The greater the difference between wire feed speeds, the more advantageous it is to adjust the welding wire buffer in a timely and appropriate manner.

[0035] According to some preferred embodiments, variants, or refinements of embodiments, the control device is configured to specify to the welding wire push motor, at least during wire feed phases of the first wire feed phase type (and / or wire feed phases of the second wire feed phase type and / or wire feed phases of the third wire feed phase type, etc.), a spooling acceleration and / or a welding wire buffer level to be achieved with this acceleration during the corresponding wire feed phase. In this way, an application-specific, controlled change in the welding wire buffer level can be achieved.

[0036] According to some preferred embodiments, variants or refinements of embodiments, the control device is set such that the adjustment of the welding wire buffer in a respective wire feed phase begins at the latest after a predetermined percentage of the respective wire feed phase has elapsed, preferably a percentage of 50% or higher, for example after a period of P60040-WQ 29.09.2025

[0037] 10

[0038] 60% of the respective wire feed phase, or 70%, 80%, 90%, or similar. This ensures that the welding wire buffer remains largely correctly set for the current wire feed phase, while simultaneously guaranteeing a timely and correct adjustment of the welding wire buffer level for the subsequent wire feed phase.

[0039] Using a percentage to determine the start of the adjustment is particularly advantageous when the wire feed phase has a variable duration and is instead limited, for example, by a fixed number of process steps or a predetermined quantity to be achieved (e.g., a certain length of a weld, a certain amount of melted welding wire, etc.).

[0040] According to some preferred embodiments, variants or refinements of embodiments, the control device is set such that the adjustment of the welding wire buffer in a respective wire feed phase begins at the latest after a predetermined period of time has elapsed since the start of the respective wire feed phase, in particular after a period of time of 10 milliseconds.

[0041] According to some preferred embodiments, variants or refinements of embodiments, the control device is set such that the adjustment of the welding wire buffer in a respective wire feed phase begins at the latest after a predetermined number of welding cycles have been carried out by the welding machine during the wire feed phase.

[0042] According to some preferred embodiments, variants or refinements of embodiments, the control unit P60040-WG 29.09.2025

[0043] 11 such that at least two wire feed phase types alternate in regular succession, and during each wire feed phase the welding wire buffer is set for the following wire feed phase.

[0044] According to some preferred embodiments, variants, or refinements of the design, the welding wire storage device is arranged between the welding wire push motor and the welding wire pull motor. The welding wire push motor and the welding wire pull motor together can also be referred to as a push-pull system. Thus, the welding wire pull motor can effect the dynamic movement of the consumable wire electrode (i.e., the leading end of the welding wire), while the welding wire push motor, largely decoupled from this, handles the unwinding and refeeding of the welding wire.

[0045] According to some preferred embodiments, variants, or refinements of the design, the control device is configured to adjust the welding wire buffer during the wire feed phases while the wire feed system is in operation and / or while a welding machine is in operation. "In operation" means that the adjustment does not take place exclusively during a welding start-up process (e.g., a process for arc ignition and / or slag removal from the welding wire), but rather in an operating mode used for actual welding tasks, particularly over a longer period of time (e.g., a weld seam).

[0046] According to some preferred embodiments, variants or

[0047] Refinements of execution forms include a P60040-WG 29.09.2025

[0048] 12

[0049] The wire core serves as a welding wire storage device, and a retraction of the welding wire within the wire core provides the welding wire buffer. In this way, the outer contour of the welding machine is advantageously not altered in any way by the present invention.

[0050] According to a second aspect, the invention provides a welding machine comprising a welding power source and a wire feed system according to an embodiment of the first aspect of the present invention. The control unit of the wire feed system can be arranged in the welding power source, in particular as part of a control device of the welding power source. However, an external wire feed system can also be provided. This increases flexibility, especially in robotic applications.

[0051] According to a third aspect, the invention also provides a method for conveying a welding wire for a welding machine, comprising at least the steps of:

[0052] Execution of a wire feed program, wherein the wire feed program comprises at least two wire feed phase types, each with at least different mean wire feed speeds of a welding wire pull motor of the welding machine; wherein the execution of the wire feed program comprises: controlling at least one welding wire push motor; and setting, in each wire feed phase of a first wire feed phase type, a welding wire buffer in preparation for each subsequent wire feed phase of a second wire feed phase type, wherein the welding wire buffer is adjusted by varying a value currently arranged in a welding wire storage device, P60040-WC 29.09.2025

[0053] 13 variable amounts of welding wire passing through the welding wire storage device are set.

[0054] Preferably, at least two wire feed phase types (optionally exactly two wire feed phase types, i.e., the first wire feed phase type and the second wire feed phase type) alternate in regular succession. Particularly preferably, the welding wire buffer for the subsequent wire feed phase is set during each wire feed phase.

[0055] According to a fourth aspect, the present invention provides a computer program product comprising executable program code which, when executed by a computing device, performs the method according to an embodiment of the third aspect of the present invention.

[0056] Such a computing device can be implemented as any device capable of performing calculations, and in particular, of executing software, an application, or an algorithm. The computing device can, for example, have at least one processing unit, such as a central processing unit (CPU) and / or a graphics processing unit (GPU) and / or a field-programmable logic gate (FPGA) and / or an application-specific integrated circuit (ASIC) and / or a combination thereof. The computing device can also have main memory, which is operationally coupled to the at least one processing unit, as well as non-volatile memory, which is operationally coupled to the at least one processing unit and the main memory.The computing facility can be implemented wholly or entirely in a local device and / or wholly or entirely in a remote system, such as in a P60040-WC 29.09.2025.

[0057] 14 remotely located servers and / or a cloud computing platform.

[0058] According to a fifth aspect, the present invention provides a non-volatile, computer-readable data storage medium comprising executable program code which, when executed by a computing device, performs the method according to an embodiment of the first aspect of the present invention.

[0059] The data storage medium can, for example, be designed as or include a semiconductor memory, such as an SSD. The data storage medium can also be a CD, DVD, Blu-ray disc, or a magnetic storage device.

[0060] According to a sixth aspect, the present invention provides a data stream comprising executable program code or designed to generate executable program code which, when executed by a computing device, performs the method according to an embodiment of the first aspect of the present invention.

[0061] Further preferred embodiments, variants and further developments of embodiments result from the dependent claims as well as from the description with reference to the figures.

[0062] Brief description of the characters

[0063] The invention is explained in more detail below with reference to exemplary embodiments in the figures of the drawings. Figure 1 shows a schematic representation of a wire feed system according to one embodiment of the present invention and of a welding machine according to another embodiment of the present invention;

[0064] Fig. 2 shows a schematic detail of a welding wire storage device of the wire feed system according to the invention in one embodiment;

[0065] Fig. 3 shows an exemplary curve of an instantaneous wire feed speed on a welding wire pull motor;

[0066] Fig. 4a) shows a possible time course of an average wire feed speed during the execution of a wire feed program according to the present invention;

[0067] Fig. 4b) shows a possible time course of a spooling speed during the execution of a wire feed program according to the present invention;

[0068] Fig. 4c) shows a graphical representation of a possible time course of a welding wire buffer during the execution of a wire feed program according to the present invention;

[0069] Fig. 4d) a variant of Fig. 4c ); P60040-WG 29.09.2025

[0070] 16

[0071] Fig. 4e) another variant of Fig. 4c);

[0072] Fig. 5 a) to c)

[0073] Graphs for the schematic explanation of a variant for carrying out the wire feed program according to Fig. 4a) -c) ;

[0074] Fig. 6 a) to c)

[0075] Graphs for the schematic explanation of another variant for carrying out the wire feed program according to Fig. 4a) -c);

[0076] Fig. 7 is a schematic flowchart to explain a method according to a further embodiment of the present invention;

[0077] Fig. 8 is a schematic block diagram of a computer program product according to one embodiment of the present invention; and

[0078] Fig. 9 shows a schematic block diagram of a data storage medium according to one embodiment of the present invention.

[0079] In all figures, identical or functionally equivalent elements and devices are designated with the same reference numerals, unless otherwise specified. The designation and numbering of the process steps do not necessarily imply a sequence, but serve for better differentiation, although in some variants the sequence may correspond to the numbering sequence.

[0080] Detailed description of the figures. Fig. 1 shows a schematic representation of a wire feed system 100 according to one embodiment of the present invention, as well as a welding machine 1000 according to another embodiment of the present invention. In Fig. 1, the welding machine 1000 is shown as a robotic welding machine; however, a configuration as a manual welding machine is also possible.

[0081] The wire feed system 100 comprises a welding wire storage device 110, which is designed such that a variable quantity of welding wire 42 currently arranged therein, passing through the welding wire storage device 110, acts as an adjustable welding wire buffer for the welding machine 1000.

[0082] The welding wire storage device 110 can be attached to a holding device 41, e.g. a balancer, as shown schematically in Fig. 1; alternatively, however, it can also be attached, for example, to a robot arm 29 or a manipulator 30 of a robot 28, or to the welding torch 10 of the welding machine 1000.

[0083] Fig. 2 shows a schematic detail view of the welding wire storage device 110, which is designed here as an angled storage device. It thus comprises an angled housing 111 through which the welding wire 42 runs within a wire core 43. The wire core 43 can run wholly or partially within a hose assembly 23 of the welding machine 1000 and / or be arranged wholly or partially in its own wire guide hose 50 (see Fig. 1). P60040-WG 29.09.2025

[0084] 18

[0085] The housing 111 is preferably formed with an angle greater than 90°, in particular greater than 100°, and preferably greater than 110°. The shallower the angle, i.e., the closer to 180°, the fewer requirements are placed on the placement of the welding wire storage device 110 in or on the hose assembly 23 or the wire guide hose 50 of the welding machine 1000. The following description will initially be continued primarily with reference to Fig. 2, but also partly with reference to Fig. 1 for the overall arrangement.

[0086] The radius of curvature R of the wire core 43, and thus (essentially) also of the welding wire 42, can be changed, for example, by allowing the wire core 43 to be freely axially displaceable at a first position xl at an end of the housing 111 facing a welding wire push motor 121 of the wire feed system 100, while it is fixed at a second position x2 at an end facing the welding torch 10 of the welding machine 1000. The wire feed speed Vd at the welding torch 10 is largely, or completely, controlled by a welding wire pull motor 129, which in the example shown is arranged on the welding torch 10.

[0087] By feeding the welding wire push motor 121 towards the housing 111 with an average unwinding speed Va, which exceeds an average wire feed speed Vd from the housing 111 towards the welding torch 10 (i.e. Va>Vd on average), the welding wire buffer in the housing 111 can be enlarged by deflecting and bending the welding wire 42 and thus the wire core 43 more strongly.

[0088] Conversely, Vd>Va reduces the average welding wire buffer and thus increases the radius R of the wire core 43 and the welding wire 42 therein.

[0089] The wire feed speed Vd at the welding torch 10 differs from the spooling speed Va at the welding wire push motor 121 on the one hand by the play of the welding wire 42 and the wire core 43 between a welding power source 200 of the welding machine 1000 and the welding torch 10, but especially typically by the action of the welding wire pull motor 129, which causes the often highly dynamic movements of the welding wire 42 at the welding torch 10.

[0090] To detect the fill level of the angle buffer, i.e., the current level of the welding wire buffer, the wire feed system 100 can include a measuring device. In the illustrated embodiment, the measuring device comprises an angle sensor, for example, an incremental encoder, a potentiometer, or the like, which is connected to the wire core 43 via a lever 112 and a rotatably mounted clamp 113, a so-called "core clip." Thus, a change in the radius R of the arc-shaped wire core 43 can be detected, whereupon a corresponding conversion of the impulses or a calculation of the welding wire buffer can take place, for example, by a control unit 130 of the wire feed system 100. The control unit 130 can be configured to regulate the welding wire buffer level based on the signal from the measuring device.

[0091] The control unit 130 can, for example, be integrated into a welding power source 200 of the welding machine 1000, as shown schematically in Fig. 1, but can also be designed separately from it.

[0092] The control unit 130 is in each case configured to execute a wire feed program, wherein the wire feed program comprises at least two wire feed phase types, each with at least different mean wire feed speeds Vd of the welding wire pull motor 129. The wire feed program is typically executed in parallel and synchronously with, or as part of, a welding program executed by a control device of the welding power source 200, so that the electrical welding parameter settings (in particular welding voltage and welding current) are correctly matched to the wire feed speed Vd of the welding wire 42 and vice versa.

[0093] Since the present invention deals primarily with wire unwinding speeds Va and wire feed speeds Vd, and less so with electrical welding parameters, these will only be mentioned occasionally herein. It is understood, however, that these are typically set. In particular, a higher-level control can be achieved by a control device of the welding power source 200, which transmits or issues instructions to the control unit 130 of the wire feed system 100.

[0094] In other possible embodiments, the wire core 43 itself can function as a welding wire storage device. The wire core 43 typically allows the welding wire 42 a certain amount of slack, which can thus be used as a welding wire buffer. An advantage of this is that no additional physical components are necessary, and the P60040-WG 29.09.2025

[0095] 21

[0096] The welding wire storage device also does not add any interfering contour to the outer contour of the welding machine 100. In contrast, the capacity of such a welding wire buffer is relatively small.

[0097] Fig. 3 illustrates an example of a wire feed program with four wire feed phases PI, P2, P3, P4 of a total of two different wire feed phase types TI, T2:

[0098] A first wire feed phase PI and a third wire feed phase P3 each correspond to a first wire feed phase type TI. This first wire feed phase type TI represents a reversing wire movement with rapidly alternating positive and negative instantaneous wire feed speeds Vd, m, which on average result in a slightly positive average wire feed speed Vd, for example, 3 m / min. In a so-called "gold metal transfer" process, for example, an arc can be ignited by retracting the welding wire 42, melting a droplet from the welding wire 42, and then depositing this droplet onto a workpiece by advancing the welding wire 42. The positive average wire feed speed Vd thus corresponds to the melting rate of the welding wire 42 in this process and continuously compensates for its consumption.

[0099] A second wire feed phase P2 and a fourth wire feed phase P4 are each of a second wire feed phase type T2. This second wire feed phase type T2 is a wire feed phase type with a constant wire feed speed Vd, for example, 10 m / min. During this time, a parallel welding program may, for example, include a pulse welding phase. In this example, the welding program is thus a mixed process (or: mix process) in which cold metal transfer phases and pulse welding phases alternate. In parallel, the wire feed program at the welding wire pull motor 121 includes the instantaneous wire feed speed profiles Vd, m shown in Fig. 3, which also defines the average wire feed speed Vd.

[0100] In this example, it is evident that at the beginning of the second and fourth wire feed phases P2 and P4, the average wire feed speed Vd increases drastically, from 3 m / min to 10 m / min. Therefore, it is highly advantageous if, at the beginning of the second and fourth wire feed phases P2 and P4, the welding wire buffer is already set to a higher level than in the first and third wire feed phases P1 and P3.

[0101] Accordingly, the control device 130 is configured according to the invention to set the welding wire buffer, at least by appropriately controlling the welding wire push motor 121 (optionally also by additionally controlling the welding wire pull motor 129), in a wire feed phase Pl, P3 of the first wire feed phase type TI in preparation for a respective subsequent wire feed phase P2, P4 of the second wire feed phase type T2.

[0102] The greater the difference between the average wire feed speeds Vd, the more pronounced the advantages of the present invention become. The invention is therefore particularly advantageous when there is a significant difference between an average wire feed speed Vd (Tl) of the first wire feed phase type TI and an average wire feed speed P60040-WG 29.09.2025

[0103] 23

[0104] Vd(T2) of an immediately following second wire feed phase type T2 is at least 0.1 m / min, preferably 1 m / min, in particular at least 5 m / min, especially preferably at least 7 m / min.

[0105] An exemplary sequence of a wire feed program according to the invention is illustrated in Fig. 4. Fig. 4 shows graphs that depict various parameters and quantities over time during the wire feed program.

[0106] Fig. 4a) shows the average wire feed speed Vd at the welding wire pull motor 129 as a function of time. Four different wire feed phases with a total of 2 different wire feed phase types are clearly recognizable. These could be, for example, the wire feed phases PI, P2, P3, and P4 from Fig. 3, i.e., with approximately average

[0107] Wire feed rates Vd ( Tl ) =Vd ( Pl ) =Vd ( P3 ) =3m / min and Vd (T2) =Vd (P2) =Vd (P4) =10m / min.

[0108] Fig. 4b) shows a spooling speed Va adapted by the inventive method on the welding wire push motor 121, which represents a slight modification of the average wire feed speed Vd from Fig. 4a). At a first time tl, the control unit 130 continuously and strictly monotonically increases the average spooling speed Va according to the wire feed program until, at a time t2 (for example, at the beginning of the subsequent wire feed phase P2), it again coincides with the average wire feed speed Vd, which is adapted to the parallel welding process. In the illustrated example, the average spooling speed is increased linearly relative to the simultaneous average wire feed speed Vd from the first time tl, typically until the end of the first wire feed phase PI.The (constant) acceleration with which the increase takes place is lower in the example shown than a higher acceleration which can subsequently be used - depending on the variant - so that the desired average unwinding speed Va is present in time at the beginning of the wire feed phases P2 , P4 of the second wire feed phase type T2.

[0109] This higher acceleration can be equal to the acceleration used simultaneously for the average wire feed speed Vd, so that, in particular, the velocity graphs of the average wire feed speed Vd and the average unwind speed Va can temporarily be the same again. This higher acceleration can be equal to a maximum acceleration of the wire feed push motor 121, whose maximum acceleration is typically smaller than a maximum acceleration of the wire feed pull motor 129.

[0110] Fig. 4c shows how the welding wire buffer is located at a first welding wire buffer level NI from the beginning of the first wire feed phase PI. The welding wire buffer is shown here as a percentage deviation from the first welding wire buffer level NI. This can be the welding wire buffer NO of a zero position (or: rest position, or: center position) of the welding wire 42 in the welding wire storage device 110. The zero position, or center position, can be characterized in particular by the fact that the welding wire buffer can be increased or decreased by the welding wire storage device by the same amount from this position.

[0111] From time 11 to time t2, the welding wire buffer is increased to a second, higher level N2, which is present at the start of the second wire feed phase P2. With the linear increase in the average unwinding speed Va relative to the average wire feed speed Vd shown in Fig. 4b), the welding wire buffer level increases quadratically from N1 to N2.

[0112] The flanks for the rise and fall of the wire feed speed Vd j at the beginning and end, as already mentioned, are typically due to the finite acceleration capability of the wire feed push motor 121; they are typically set as steep as possible so that these transitions can be considered instantaneous in some variants.

[0113] The time tl at which the setting of the welding wire buffer for the subsequent wire feed phase P2, P4 begins can be determined in many different ways, which is selected or determined depending on the application and especially depending on a parallel welding phase.

[0114] For example, the time tl can begin after a predetermined time interval following the start of the respective wire feed phase Pl, P3, for instance, after a time interval of 10 milliseconds. It can also be provided that the time tl begins no later than the elapsed time of a predetermined percentage of the respective wire feed phase Pl, P3, preferably a percentage of 50% or higher, for example, after 60%, 70%, 80%, 90%, or the like of the respective wire feed phase.

[0115] It is also possible that the time tl is dependent on a parallel welding program. For example, the time tl can occur at the latest after the welding machine has completed a predetermined number of welding cycles. If the parallel welding phase of the welding program is a pulsed welding phase, the time tl can be set to occur at the latest after a predetermined number of welding pulses. In a welding phase with oscillating wire feed, such as the aforementioned cold metal transfer phase, this can be set, for example, after a predetermined number of oscillation periods.

[0116] In the example shown, during the wire feed phases P2, P4 of the second wire feed phase type T2, a reduction in the constant unwinding speed Va occurs compared to the constant average wire feed speed Vd (i.e. Va ( T2 ) <Vd ( T2 ) ) sodass der Schweißdrahtpuffer in den Drahtvorschubphasen P2, P4 des zweiten Drahtvorschub- Phasentyps T2 linear wieder abgebaut wird und zu Beginn der Drahtvorschubphasen Pl, P3 des ersten Drahtvorschub-Phasentyps Tl wieder in der Nulllage ist, wie in Fig. 4c) ersichtlich ist. Auf diese Weise wird eine periodische Abfolge der Drahtvorschubphasen sowie, von etwaigen kurzfristigen Schwankungen abgesehen, auch des Schweißdrahtpufferniveaus erzielt. Va(T2) kann hier beispielsweise zwischen 50% und 90% von Vd(T2) liegen, insbesondere zwischen 70% und 85% von Vd (T2) .However, as explained in detail above, the welding wire buffer can be adjusted for each subsequent wire feed phase P1-P4 in wire feed phases P1-P4 of several wire feed phase types TI, T2, or even in each wire feed phase P1-P4.

[0117] Fig. 4d) shows a variant of the method described above, in which the welding wire buffer is offset from the zero position. The first welding wire buffer level NI is reduced relative to this, and the second welding wire buffer level N2 is increased relative to it. In the variant shown, a welding wire level NO of the zero position is not located midway between the two welding wire buffer levels NI and N2, but is closer to the increased second welding wire buffer level N2 than to the reduced first welding wire buffer level NI.

[0118] Fig. 4e) shows another variant in which the welding wire buffer is set to a corresponding welding wire buffer level NI, N2 at the beginning of each subsequent wire feed phase P1-P4, with all welding wire buffer levels NI, N2 differing from the welding wire level NO of the zero position.

[0119] Figures 5a) to 5c) each show the same size as the corresponding figure in Figures 4a) to 4c), according to a further variant of the wire feed program according to the invention.

[0120] In the variant according to Figures 5a) to 5c), the average unwinding speed Va during the wire feed phases P2, P4 of the second wire feed phase type T2 is not constant (as, for example, in Fig. 4b) ), but is reduced linearly during each of the wire feed phases P2, P4 of the second wire feed phase type T2. As a result, as can be seen in Fig. 5c), the welding wire buffer level decreases quadratically from the second welding wire buffer level N2 back to the first welding wire buffer level NI (here: the zero position NO).

[0121] In the variant shown in Fig. 5b), the linear reduction begins right at the start of the wire feed phases P2, P4 of the second wire feed phase type T2, for example starting with the same value that the average wire feed speed Vd(T2) of the welding wire push motor 121 has at this time, and then linearly to a value Va(T2) with 0 <Va ( T2 ) <Vd ( T2 ) abfallend. Auch der hier verwendete Wert Va(T2) kann beispielsweise zwischen 50% und 90% von Vd(T2) liegen, insbesondere zwischen 70% und 85% von Vd (T2) .

[0122] Fig. 6a) to Fig. 6c) shows another variant of the wire feed program according to the invention.

[0123] In the variant shown in Figure 6b), the linear decay during the wire feed phases P2, P4 of the second wire feed phase type T2 does not begin immediately at the start of the respective wire feed phase P2, P4 (at time t3), but only later, here at time t4. Depending on the variant, time t4 can be determined, for example, by a predetermined percentage of the corresponding wire feed phase P2, P4 having elapsed, or after a predetermined time period has elapsed, or a predetermined number of welding cycles have been performed, or the like.

[0124] The start of the wire feed phases P2, P4 of the second wire feed phase type T2 can occur between t3 and t4 for the average unwinding speed Va either with the same value as the simultaneous average wire feed speed Vd(T2), as shown in Fig. 6b (which is why the welding wire buffer level initially remains at N2), or with a lower value (which would lead to a linear decrease in the welding wire buffer level). The value Va(T2) used here can also be, for example, between 50% and 90% of Vd(T2), and in particular between 70% and 85% of Vd(T2).

[0125] Fig. 7 shows a schematic flowchart to explain a method according to the third aspect of the present invention, i.e., a method for feeding welding wire to a welding machine. The method can be carried out with a wire feed system 100 and / or a welding machine 1000 of the present invention and is therefore adaptable according to all options, variants, embodiments, and further developments described with reference to the wire feed system 100 and / or the welding machine 1000, and vice versa. The method can also be carried out independently. For clarity, various reference numerals are used below, which refer to the embodiments described above.

[0126] In step S 100 of the procedure, a wire feed program is executed, wherein the wire feed program comprises at least two wire feed phase types TI, T2, each with at least different mean wire feed speeds Vd of a welding wire pull motor 129 of the welding machine 1000. A multitude of possible wire feed programs of varying composition have already been described above. P60040-WC 29.09.2025

[0127] 30

[0128] The execution of S100 of the wire feed program comprises a step S110, in which at least one welding wire push motor 121 is controlled, and a step S120, in which, in a respective wire feed phase Pl, P3 of a first wire feed phase type TI, a welding wire buffer is set in preparation for a respective subsequent wire feed phase P2, P4 of a second wire feed phase type T2, wherein the step S120 can be carried out, among other things - or completely - within the framework of the control in step S110.

[0129] In any case, in step S120, the welding wire buffer is adjusted by varying the variable quantity of welding wire 42 currently stored in a welding wire storage device 110 and traversing the welding wire storage device 110. This can be done, for example, as already explained in detail above with reference to Figures 1-4.

[0130] Fig. 8 shows a schematic block diagram of a computer program product 300 according to an embodiment of the fourth aspect of the present invention. The computer program product 300 comprises executable program code 350, which, when executed (e.g., by a processing unit), is configured to execute the method according to a

[0131] to carry out or control the implementation of the present invention, for example according to one of the variants from Fig. 4 c) -e).

[0132] Fig. 9 shows a schematic block diagram of a non-volatile, computer-readable data storage medium 400 according to an embodiment of the present invention. The data storage medium 400 comprises executable program code 450, which, when executed (e.g., by a processing unit), is configured to carry out or control the method according to an embodiment of the present invention, for example, according to one of the variants from Fig. 4 c) - e).

[0133] The non-volatile, computer-readable data storage medium 400 may, for example, be designed as or comprise a semiconductor memory, e.g., an SSD memory chip. The data storage medium 400 may also comprise or comprise a CD, DVD, Blu-ray disc, or a magnetic storage device.

[0134] The foregoing description of the disclosed embodiments merely contains examples of possible implementations, which are described to enable a person skilled in the art to manufacture or use the present invention. Various variations and modifications of these embodiments are readily apparent to a person skilled in the art – upon knowledge of the present invention – and the general principles defined herein can be applied to other embodiments without departing from the scope of the present disclosure.

[0135] Therefore, the present invention is not to be limited to the specific embodiments shown herein, but is to be granted the broadest scope that is consistent with the principles and features disclosed herein. P60040-WC 29.09.2025

[0136] 32

[0137] Reference character list

[0138] 10 welding torches

[0139] 23 Hose package

[0140] 28 robots

[0141] 29 robot arm

[0142] 30 Manipulator

[0143] 41 Holding device

[0144] 42 welding wire

[0145] 43 wire core

[0146] 50 wire guide hose

[0147] 100 wire feed system

[0148] 110 welding wire storage device

[0149] 111 Housings

[0150] 112 levers

[0151] 113 Terminal

[0152] 121 Welding wire push motor

[0153] 129 Welding wire pull motor

[0154] 130 Control unit

[0155] 200 welding power source

[0156] 300 computer programs

[0157] 350 program code

[0158] 400 data storage medium

[0159] 450 program code

[0160] 1000 welding machine

[0161] NO welding wire buffer level of the zero position

[0162] NI first welding wire buffer level

[0163] N2 second welding wire buffer level

[0164] PI first wire feed phase

[0165] P2 second wire feed phase P3 third wire feed phase

[0166] P4 fourth wire feed phase

[0167] R radius of curvature tl first time t2 second time t3 time t4 time

[0168] First wire feed phase type

[0169] T2 second wire feed phase type Va unwinding speed of the welding wire push motor

[0170] Vd wire feed speed of the welding wire pull motor xl first position x2 second position

Claims

1. - 34 - Patent claims 1. Wire feed system (100) for a welding machine (1000), comprising at least: a welding wire storage device (110) which is designed such that a variable quantity of welding wire (42) currently arranged therein, which is passing through the welding wire storage device (110), acts as an adjustable welding wire buffer; a welding wire push motor (121) by means of which the welding wire (42) can be conveyed to the welding wire storage device (100); a welding wire pull motor (129) by means of which the welding wire (42) can be conveyed away from the welding wire storage device (100);and a control device (130) which is configured to execute a wire feed program, wherein the wire feed program comprises at least two wire feed phase types, each with at least different mean wire feed speeds (Vd) of the welding wire pull motor (129), wherein the control device (130) is also configured to set the welding wire buffer, at least by appropriately controlling the welding wire push motor (121), in a wire feed phase (Pl, P3) of a first wire feed phase type (TI) in preparation for a subsequent wire feed phase (P2, P4) of a second wire feed phase type (T2), and wherein the control device (130) is configured such that at least two wire feed phase types (TI, T2) alternate with each other in regular sequence, and during each wire feed phase (PI, P2, P3, P4) the; 35 Welding wire buffer is set for each subsequent wire feed phase (PI, P2, P3, P4).

2. Wire feed system (100) according to claim 1, wherein the first wire feed phase type (TI) has a first average wire feed speed of the welding wire pull motor (129); and wherein the control device (130) is configured to increase the welding wire buffer from a first welding wire buffer level (NI) to a second welding wire buffer level (N2) in each wire feed phase (Pl, P3) of the first wire feed phase type (TI) if the second wire feed phase type (T2) has a second average wire feed speed (Vd) of the welding wire pull motor (129) which is higher than the first average wire feed speed (Vd).

3. Wire feed system (100) according to claim 2, wherein the control device (130) is configured to adjust the welding wire buffer to the first welding wire buffer level (NI) at the latest at the beginning of wire feed phases (Pl, P3) of the first wire feed phase type (TI), and to the second welding wire buffer level (N2) at the latest at the beginning of wire feed phases (P2, P4) of the second wire feed phase type (T2).

4. Wire feed system (100) according to claim 2 or 3, wherein the control device (130) is configured to reduce the welding wire buffer from the second welding wire buffer level (N2) to the first welding wire buffer level (NI) in each wire feed phase (P2, P4) of the second wire feed phase type (T2), if a wire feed phase (Pl, P2) of the first wire feed phase type (TI) follows, or to reduce to a third welding wire buffer level which is lower than the second welding wire buffer level (N2) if each wire feed phase (P2, P4) of the second wire feed phase type (T2) is followed by a wire feed phase of a third wire feed phase type which has a third average wire feed speed (Vd) of the welding wire pull motor (129) which is lower than the second average wire feed speed.

5. Wire feed system (100) according to one of claims 2 to 4, wherein the absolute difference between a mean wire feed speed (Vd) of the first wire feed phase type (TI) and a mean wire feed speed (Vd) of the second wire feed phase type (T2) is at least 0.1 m / min, preferably 1 m / min, in particular at least 5 m / min, and most preferably at least 7 m / min.

6. Wire feed system (100) according to one of claims 1 to 5, wherein the control device (130) is configured to specify to the welding wire push motor (121) at least during wire feed phases (Pl, P3) of the first wire feed phase type (TI) a wire unwinding acceleration (Va) and / or a welding wire buffer level (N2) to be achieved with this during the corresponding wire feed phase (Pl, P3).

7. Wire feed system (100) according to one of claims 1 to 6, wherein the control device (130) is set such that the setting of the welding wire buffer in a respective Wire feed phase (PI, P2, P3, P4) at the latest upon expiry of a predetermined percentage of the respective Wire feed phase (PI, P2, P3, P4) begins, preferably at a percentage of 50% or higher.

8. Wire feed system (100) according to one of claims 1 to 7, wherein the control device (130) is set such that the adjustment of the welding wire buffer in a respective wire feed phase (PI, P2, P3, P4) begins at the latest after a predetermined time period has elapsed since the start of the respective wire feed phase (PI, P2, P3, P4), in particular after a time period of 10 milliseconds.

9. Wire feed system (100) according to one of claims 1 to 8, wherein the control device (130) is set such that the adjustment of the welding wire buffer in a respective wire feed phase (PI, P2, P3, P4) begins at the latest after a predetermined number of welding cycles have been carried out by the welding machine (1000) during the wire feed phase (PI, P2, P3, P4).

10. Wire feed system (100) according to one of claims 1 to 9, wherein the control device (130) is configured to control the welding wire buffer during the wire feed phases (PI, P2, P3, P4) during operation of the to adjust the wire feed system (100) and / or during the operation of a welding machine (1000).

11. Wire feed system (100) according to one of claims 1 to 10, wherein a wire core (43) acts as a welding wire storage device for the welding wire (42), and a wire play of the welding wire (42) in the wire core (43) provides the welding wire buffer.

12. Welding machine (1000) comprising a welding power source (200) and a wire feed system (100) according to one of the Claims 1 to 11, wherein the control device (130) of the wire feed system (100) is arranged in the welding power source (200), in particular as part of a control device of the welding power source (200).

13. Method for conveying a welding wire (42) for a Welding machine (1000) , comprising: Executing (S100) a wire feed program, wherein the wire feed program comprises at least two wire feed phase types (TI, T2) each with at least different mean wire feed speeds (Vd) of a welding wire pull motor (129) of the welding machine (1000); wherein the execution of the wire feed program comprises: controlling (S110) at least one welding wire push motor (121); and Setting (S120) , in a respective Wire feed phase (Pl, P3) of a first wire feed phase type (TI) , a welding wire buffer preparing for a subsequent wire feed phase (P2, P4) of a second wire feed phase type (T2) , wherein at least two wire feed- Phase types (TI, T2) alternate in regular sequence, and during each wire feed phase (Pl, P2, P3, P4) the welding wire buffer for the following wire feed phase (PI, P2, P3, P4) is set, and wherein the welding wire buffer is adjusted by varying a variable quantity of wire currently arranged in a welding wire storage device (110) of the welding wire- 39 Storage device (110) is set by the welding wire (42) passing through it.

14. The method of claim 13, wherein the first wire feed phase type (TI) has a first average wire feed speed of the welding wire pull motor (129); and wherein the welding wire buffer in each wire feed phase (PI, P3) of the first wire feed phase type (TI) is increased from a first welding wire buffer level (NI) to a second welding wire buffer level (N2) if the second wire feed phase type (T2) has a second average wire feed speed (Vd) of the welding wire pull motor (129); Motors (129) exhibits a value higher than the first average wire feed rate (Vd) .

15. Computer program product (300) comprising executable program code (350) which, when executed by a computing device, is designed to perform the method according to claim 13 or 14.