Apparatus and system for wire feeding

Abstract

A system, apparatus, and method are provided herein for wire feeding, and more particularly, to an apparatus and system for feeding a plurality of wire strands from wire spools into molten metal for the precise formation of alloys. A system for feeding a plurality of wire strands includes: a first vertically oriented shaft; a first spool defining a groove and attached to and rotated by the first vertically oriented shaft; a first follower assembly and a third follower assembly, where the first follower assembly is configured to engage the first spool on a first side, where the third follower assembly is configured to engage the first spool on a second side.

Description

TECHNOLOGICAL FIELD

[0001] Embodiments of the present disclosure relate generally to an apparatus and system for wire feeding, and more particularly, to an apparatus and system for feeding a plurality of wire strands from wire spools into molten metal for the precise formation of alloys.BACKGROUND

[0002] The process of metal making metal and alloys therefrom is centuries old and has involved various processes over the years. More recently, alloy manufacture has involved the introduction of known quantities of solid metal into a molten metal bath to form the alloy. The solid material is generally in the form of a wire or cored wire and is fed in by length, with a defined unit of length corresponding to a predetermined volume of the component being added.

[0003] To facilitate this feeding of a wire, wire feeding machines may be employed, where a wire feeding machine feeds a length of wire from a spool of wire to a molten bath, such as a ladle. Wire feeding is challenging as the wire itself is stiff and often received in coils disposed about spools. The feeding of the wire involves pulling and straightening the wire from the coil, while simultaneously accurately feeding a specific length of the wire to obtain a proper volume of material being added. This is challenging and failure to properly feed the wire can result in alloys of improper compositions, which can be costly to rectify.BRIEF SUMMARY

[0004] A system and apparatus are provided herein for wire feeding, and more particularly, to an apparatus and system for feeding a plurality of wire strands from wire spools into molten metal for the precise formation of alloys. Embodiments include a system for feeding a plurality of wire strands including: a first vertically oriented shaft; a first spool defining a groove and attached to and rotated by the first vertically oriented shaft; a first follower assembly and a third follower assembly, where the first follower assembly is configured to engage the first spool on a first side, where the third follower assembly is configured to engage the first spool on a second side.

[0005] The system of an example embodiment further includes: a second vertically oriented shaft; a second spool defining a groove attached to and rotated by the second vertically oriented shaft; a second follower assembly and a fourth follower assembly, where the second follower assembly is configured to engage the second spool on a first side, and where the fourth follower assembly is configured to engage the second spool on a second side. According to certain embodiments wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction.

[0006] According to some embodiments wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction. The system of some embodiments further includes: a third spool defining a groove and attached to and rotated by the first vertically oriented shaft; a fourth spool defining a groove attached to and rotated by the second vertically oriented shaft; a fifth follower assembly and a sixth follower assembly, where the fifth follower assembly is configured to engage the third spool on a first side, where the sixth follower assembly is configured to engage the fourth spool on a first side; a seventh follower assembly and an eighth follower assembly, where the seventh follower assembly is configured to engage the third spool on a second side, and where the eighth follower assembly is configured to engage the fourth spool on a second side.

[0007] According to some embodiments wire is fed along a third channel, parallel to and offset from the first channel, in response to the wire being captured between the fifth follower assembly and the third spool and the sixth follower assembly and the fourth spool and the third spool and fourth spool rotating in a first direction; and where wire is fed along a fourth channel, parallel to and offset from the first channel, in response to the wire being captured between the seventh follower assembly and the third spool and the eighth follower assembly and the fourth spool and the third spool and fourth spool rotating in a second direction, opposite the first direction.

[0008] According to some embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and where the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The system of some embodiments further includes a cabinet, where the first spool and second spool are disposed within the cabinet, the system further including a motor disposed in a base of the cabinet, where the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft. The system of some embodiments further includes at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool.

[0009] Embodiments provided herein include a module for a wire feeder including: a first spool defining a groove configured to be attached to and rotated by a first vertically oriented shaft; a second spool defining a groove configured to be attached to and rotated by a second vertically oriented shaft, parallel to the first vertically oriented shaft; a first follower assembly and a second follower assembly, where the first follower assembly is configured to engage the first spool on a first side, where the second follower assembly is configured to engage the second spool on a first side; and a third follower assembly and a fourth follower assembly, where the third follower assembly is configured to engage the first spool on a second side, where the fourth follower assembly is configured to engage the second spool on a second side.

[0010] According to certain embodiments wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction. According to certain embodiments wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction.

[0011] According to some embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and where the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The module of some embodiments further includes at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool. Some embodiments described herein include a wire feeder configured to receive within a cabinet the above-described module. According to certain embodiments the cabinet is configured to receive two or more of the above-described module. According to some embodiments the two or more of the above-described modules are stacked vertically along the first vertically oriented shaft and the second vertically oriented shaft.

[0012] Embodiments provided herein include a system for feeding a plurality of wire strands including: a first channel, wherein the first channel passes between a groove of a first spool and a first follower assembly, and between a groove of a second spool and a second follower assembly; a second channel, wherein the second channel passes between the groove of the first spool and a third follower assembly, and between the groove of the second spool and a fourth follower assembly, where the first channel and the second channel are parallel to and offset from one another, where the first spool rotates about a first vertically oriented shaft, where the second spool rotates about a second vertically oriented shaft, and where the first vertically oriented shaft and the second vertically oriented shaft are parallel to and offset from one another.

[0013] According to certain embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and wherein the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The system of some embodiments further comprises a cabinet, where the first spool and second spool are disposed within the cabinet, the system further including: a motor disposed in a base of the cabinet, wherein the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft.

[0014] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments; further details of which can be seen with reference to the following description and drawings.BRIEF DESCRIPTION OF DRAWINGS

[0015] Having thus described certain embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0016] FIG. 1 illustrates a complete wire feeder according to an example embodiment of the present disclosure;

[0017] FIG. 2 illustrates the wire feeder of FIG. 1 with the access doors, control panel, and base removed according to an example embodiment of the present disclosure;

[0018] FIG. 3 illustrates the wire feeder of FIG. 2 with the support frame hidden according to an example embodiment of the present disclosure;

[0019] FIG. 4 illustrates a module of a wire feeder and the driving motor according to an example embodiment of the present disclosure;

[0020] FIG. 5 illustrates a top view of a module of a wire feeder according to an example embodiment of the present disclosure;

[0021] FIG. 6 illustrates a top view of one channel of a module of a wire feeder according to an example embodiment of the present disclosure; and

[0022] FIG. 7 illustrates a perspective view of one channel of a module of a wire feeder according to an example embodiment of the present disclosure.DETAILED DESCRIPTION

[0023] The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0024] Metal processing such as in the steel industry it is necessary to supply a length of metal wire in precise amounts to obtain the metal composition desired. The metal wire can be powdered alloy cored wire, commonly referred to as “cored wire” or solid metal wire often referred to as “rod” such as aluminum rod or calcium rod. A machine is generally used to supply the metal wire in a manner that is repeatable and consistent in delivering the appropriate amount of wire as determined based on diameter and length. Cored wire is often used to supply the appropriate components to the metal being formed, such as when producing alloys of steel. Alloys are generally produced using different components to change the properties of the alloy for different use cases. Different alloys of steel are employed in different products to achieve the appropriate strength, durability, machinability, ductility, and corrosiveness among other properties. The use of cored wire enables the production of alloyed steel in a manner that can precisely control the amount of each component of the alloy that is being added.

[0025] The production of cored wire and solid wire is generally performed by compressing metal into an elongate wire form factor. Cored wire typically involves a metal casing compressed about a powdered metal core. Cored wire and solid wire, collectively referred to herein as “wire”, is produced with an elongate body having a consistent diameter such that a length of that cylindrical wire includes a known amount of the metal component—whether cored or solid. This enables the component to be added in the formation of metal based on a length as the length of wire directly corresponds with a volume or mass of that component. Thus, accurate feeding by length using a wire feeder can accurately control a mass of the constituent elements of the wire to be supplied during metal alloy formation.

[0026] In large scale manufacturing, the use of wire involves large coils of wire fed into a furnace or ladle using a wire feeder to provide a precise amount of length of the wire during the metal forming process. Wire feeding machines are programmed to introduce a precise amount of wire to satisfy the requirements of the alloy being formed. This can be challenging as the spools of wire are generally large and exceedingly heavy, such that pulling wire from the spool requires significant force to unwind and straighten wire from the spool.

[0027] The process of metal alloy formation can involve the use of various components that can each be provided via wire via a wire feeding machine. According to embodiments described herein, the wire feeder can include one or more channels, with each channel capable of feeding wire. Each channel is capable of supplying a unique wire component, though high-use components may be fed via multiple channels of the wire feeder described herein.

[0028] FIG. 1 illustrates an example embodiment of a wire feeder 100 as described herein. The wire feeder 100 shown includes a structural frame 105, a base 110, a cabinet 115 with a wire inlet side 120 and a wire exit side 130 of the cabinet. Also shown is the control panel 140 which together with the human-machine interface (HMI) can be used to control the various functions of the wire feeder 100 as described further below. The illustrated embodiment further includes forklift pockets 150 that are integrated into the structural frame 105 to enable mobility of the wire feeder within a facility or between facilities. Access doors 145 are positioned on the front of the cabinet and can be opened to access an interior of the cabinet. Also shown are wire exit guides 135, with each wire exit guide being associated with a respective channel of the wire feeder 100. The wire feeder 100 of the illustrated embodiment is two-sided, with access doors provided on a back side of the wire feeder cabinet 115 in the view shown such that the channels disposed on an opposite side of the cabinet can be accessed as described herein.

[0029] FIG. 2 illustrates the wire feeder 100 of FIG. 1 with the base 110, access doors 145, HMI 147, and control panel 140 removed for ease of understanding. With the access doors 145 removed, the interior of the cabinet 115 is visible. When the access doors 145 are opened by an operator, the operator can access the components shown in FIG. 2 of the cabinet 115. Below the cabinet 115 and within the base 110 is a motor 160. The motor 160 drives an input shaft of the gearbox 165 which translates the rotation of the motor into rotation about a vertical axis, which is used to drive the drive gears described further below.

[0030] FIG. 3 illustrates the wire feeder 100 of FIG. 2, with the structural frame 105 and cabinet 115 removed. As shown, the motor 160 drives an input shaft of the gearbox 165 which is supported on the structural frame by the gearbox bracket 167. The gearbox 165 translates the rotation from the input shaft to rotation about a vertical axis in driving gear 170. Gear 170 drives the belt 180 (or chain) which is engaged with first driven gear 175 and a second driven gear 185. As the first driven gear 175 is driven, it rotates first shaft 190, and as the second driven gear 185 is driven, it rotates the second shaft 195. The first shaft 190 and second shaft 195 can rotate within bearings supported by the cabinet 115 and structural frame 105. The first driven gear 175 and second driven gear 185 are of equal size such that they rotate at the same rate of rotation whereby the rotation of the first shaft 190 and second shaft 195 are synchronized. The motor 160 is capable of rotating in both a forward and reverse direction, which in turn causes the first shaft 190 and second shaft 195 to rotate in both a first direction and a second direction as described further below.

[0031] The wire feeder 100 of FIGS. 1-3 includes eight channels for feeding up to eight spools of wire. Embodiments of the wire feeder described herein include a modular design such that the number of channels can be increased or decreased as needed based on the needs of the end user. The embodiment of FIGS. 1-3 includes four modules stacked vertically along the first shaft 190 and the second shaft 195, with each module employing two channels of the wire feeder 100. A first channel of each module is disposed on a first side of the wire feeder 100 and on a first side of the first spool 210 and second spool 215, while a second channel of the same module is disposed on a second side of the wire feeder, on a second side of the first spool and the second spool as illustrated below.

[0032] FIG. 4 illustrates the wire feeder of FIGS. 1-3 with three of the modules removed to leave a single module for ease of understanding. As shown, the module depicted in FIG. 4 includes a first spool 210 attached to the first shaft 190 and a second spool 215 attached to the second shaft 195. Also shown in FIG. 4 are a first pair of hinge rods 220 and a second pair of hinge rods 225. The hinge rods support follower assemblies 230 that function together with the spools to grab and feed wire through the wire feeder 100.

[0033] FIG. 5 illustrates a top view of a module 200 of embodiments of the wire feeder described herein. The top view illustrates the first spool 210 that rotates about the first shaft 190 and the second spool 215 that rotates about the second shaft 195. There are four follower assemblies 230 on each module, each follower assembly hingedly attached to a respective hinge rod. The hinge rods are supported by the structural frame of the wire feeder as shown in FIGS. 1-3. Also shown in FIG. 5 are the paths for the wire that is fed through the wire feeder. A first path 240 of the first channel is shown by a first dotted line while a second path 250 of the second channel of the illustrated module is shown by another dotted line. These paths are through a respective wire inlet 235, between a first follower assembly 230 and the first spool 210, between a second follower assembly 230 and the second spool 215, and out through the wire exit guides 135. The follower assemblies 230 press the wire into engagement with a respective spool such that the surface of the spool can pull the wire through the wire feeder.

[0034] FIG. 6 illustrates a top view of the partial module 200 with only one wire feed side of the module depicted. As shown, the first spool 210 and the second spool 215 are mounted to the first shaft 190 and the second shaft 195 respectively. The follower assemblies 230 are shown in the open position where a follower wheel 232 is not engaged with a respective spool. The follower assemblies are rotated to the open position about the hinge rods 220. The follower assemblies 230 are rotated to the open position to enable loading of a wire into the wire path through the wire feeder with the first path 240 illustrated in dotted lines.

[0035] To start a wire within the wire feeder as described herein the access doors of the wire feeder shown in FIG. 1 may be moved to the open position to access the inside of the cabinet. The follower assemblies 230 can then be rotated to the open position shown in FIG. 6. With the follower assemblies 230 in the open position shown, a first guide channel 262, a second guide channel 264, and third guide channel 266 can be opened. These channels provide guides for the wire as it passes through the wire feeder and prevents the wire from deviating from the path through the feeder. A wire can be introduced to the wire feeder through the wire inlet 235, through the first guide channel 262, into a groove of the first spool 210, through the second guide channel 264, into a groove of the second spool 215, through the third guide channel 266, and out the wire exit guide 135. The first guide channel 262, second guide channel 264, and third guide channel 266 may each be openable to open a side of the guide channel facing the open access doors of the cabinet to provide an operator access to the guide channels. However, the guide channels do not necessarily need to be opened for feeding of the wire.

[0036] With the wire within the grooves of the first spool 210 and the second spool 215, the follower assemblies 230 can be rotated from the open position shown in FIG. 6 to a closed position as shown in FIG. 5. The follower assemblies can be locked in the closed position, such as using a separate locking mechanism (e.g., a pin) or through other locking mechanisms to hold the follower assemblies in the closed position. This closing of the follower assemblies 230 pinches the wire between the follower assemblies 230 and a respective spool.

[0037] The follower assemblies 230 each include a follower wheel 232 which is what contacts the wire and pushes the wire into the groove of the spool. A cylinder 234, which can be hydraulic, pneumatic, or electric, operates to push against lever arm 236 which supports the follower wheel 232. This pushing or first force imparted by the cylinder 236 drives the wheel 232 in the direction of arrow 238 into the groove of the spool to capture the wire between the follower wheel 232 and the groove of the spool. The groove extends about a circumference of the spool. The groove within the first spool 210 and the groove within the second spool 215 can be curved or in a V-shape, however, the groove includes a textured or ridged surface to help grab and pull wire using the grooves of the spools. When the follower assemblies 230 are in the closed position, and the cylinder 234 presses or biases the lever arm 236, the follower wheel 232 is pressed into the groove which results in the wire being securely grasped by the spool which enables the spool to pull the wire.

[0038] FIG. 7 illustrates a perspective view of the partial module 200 depicting the follower assemblies 230 on a single side of the spools. The follower assemblies 230 of the illustrated embodiment of FIG. 7 are shown in the closed position, with the follower wheel 232 of each follower assembly engaged with a respective spool, such as the first spool 210 and the second spool 215. Also visible in FIG. 7 is a first groove 212 of the first spool and a second groove 217 of the second spool 215. In the illustrated closed position of the follower assemblies, the cylinder 234 drives the lever arm 236 to press the follower wheel into the groove of the respective spool, thereby driving the wire within the groove into engagement with the textured or ridged surface within the groove. This cooperation ensures that the wire captured between the follower wheel 232 and the groove of the spool remains engaged with the spool and does not slip as the spool pulls the wire through the wire feeder of embodiments described herein.

[0039] It is important for embodiments of the wire feeder of example embodiments to securely grip the wire being fed through the wire feeder. This ensures that the spool does not slip relative to the wire. With the wire being securely gripped between a follower wheel 232 and a groove of the first spool 210 or the second spool 215 enables accurate feeding of the wire as each rotation or portion thereof for a spool will translate into a length of wire being fed from the wire feeder. If the wire were to slip within the groove, accurate wire mass feeding would be compromised since the length of wire fed would not correspond to a degree of rotation of a spool.

[0040] Wire feeding in example embodiments often employs a spool of wire as a source from which the wire feeder pulls the wire. Alloy wire is relatively thick in diameter and thus a spool of such wire is resistant to straightening. Pulling such a wire through a wire feeder requires significant force and a solid grasp on the wire as it is pulled from the spool and straightened. Embodiments described herein provide such solid grip and the motor driving the first spool 210 and the second spool 215 provides sufficient power to pull the wire from the spool and feed the wire through the wire exit 135.

[0041] In addition to the efficient and effective wire feeding described above, embodiments are uniquely configured to be modular in such a way as to enable multiple channels of the wire feeder to be implemented as needed. Referring back to the module 200 depicted in FIG. 5, the module 200 includes the first path 240 shown by the first dotted line and the second path 250 shown by the second dotted line. Wire is not fed along the first path 240 and the second path 250 at the same time. Conversely, wire will be fed from one path or the other, as the first spool 210 and the second spool 215 rotate in different directions based on which wire feed path is being used. To feed wire along the first path 240 and not the second path 250, the follower assemblies 230 associated with the second path 250 may be disengaged. The follower assemblies can be disengaged, for example, by retracting cylinder 234 which in turn pulls on lever arm 236 (applying a second force) which pulls the follower wheel 232 away from the groove of the spool. Optionally, the follower assemblies of a path not being used may be moved to the open position shown in FIG. 6 or a partially open position as needed. If there is a wire along the path not being used, disengagement of the follower assemblies 230 would result in the wire failing to be grasped by the respective spool, such that rotation direction of the spool does not impact the wire along that path.

[0042] While embodiments described above describe a pushing force of the cylinder 234 driving the follower wheel 232 into engagement with the cylinder and a pulling force of the cylinder pulling the follower wheel 232 away from engagement with the spool, such a cylinder can be arranged in a different orientation in which a first force, be it a pushing force or a pulling force, presses the follower wheel 232 into engagement with the spool while a second force, be it a pushing force or a pulling force, moves the follower wheel 232 out of engagement with the spool.

[0043] To feed wire along the first path 240 the first spool 210 and the second spool 215 would rotate in a counterclockwise direction, pulling the wire toward the wire exit 135 while the follower assemblies 230 of the first path 240 are engaged and while follower assemblies 230 of the second path 250. To feed wire along the second path 250, the first spool 210 and the second spool 215 would rotate in the clockwise direction while the follower assemblies 230 along the second path 250 are engaged and the follower assemblies along the first path 240 are disengaged.

[0044] Access to each wire feed channel is a key benefit of example embodiments described herein. The illustration of FIG. 2 demonstrates the accessible nature of the modules of the wire feeder 100 of example embodiments described herein. The modules allow for expansion of capacity of the wire feeder 100 by adding additional wire feed channels. These are added in a vertical arrangement, with four modules visible in the embodiment of FIG. 2, each module including two wire feed channels. Arranging these modules vertically provides access to each wire feed channel through access doors on the front and the rear. Each wire feed channel of a side is accessible without requiring reaching over other wire feed channels, and each wire feed channel is readily accessible to address obstructions, feeding of new wire, and maintenance of the components of each wire feed channel. This arrangement is distinct from any previous wire feeders.

[0045] Embodiments described herein are modular in that multiple wire feed paths may be employed beyond the two wire feed paths per module. The configuration of embodiments described herein provide a unique advantage over prior wire feeders as the spools are arranged to rotate about vertical axes, which enables additional modules to be incorporated without altering a footprint of the wire feeder. Additional modules stack vertically atop other modules to form a stack of modules sufficient to satisfy the needs of a user. Maintaining the same footprint with increased wire feeding capacity allows the use of more wire feeding paths within the same floorspace of a facility. Further, additional motors to drive the wire feeding are not necessary, since the motor and gearbox positioned beneath the modules as depicted in FIGS. 2-4 is capable of driving the spools of each module.

[0046] Manufacturers of steel alloys require substantial quantities of wire. Wire is now mass produced for alloy manufacture at scale to satisfy the needs of the industry. Wire is produced in long lengths of wire that is typically wound about a reel for transportation, distribution, and consumption. However, working with such spools of wire is cumbersome, particularly in the mass production of steel where accurate alloy production requires precise lengths of cored metal alloy wires to be added to liquid metal, such as into a ladle prior to casting.

[0047] Embodiments described herein provide a modular wire feeder that can scale with the needs of a facility while being capable of accurately feeding precise lengths of wire during metal making even on a large industrial scale.

[0048] Embodiments of the wire feeder described herein are not only modular and hence scalable, but they are also more easily maintained than existing wire feeders. With the module configuration and each module including wire channels readily accessible through access doors without requiring reach or crossing the path of another channel. Further, modules described herein are each driven by a single motor, such that the cost of embodiments described herein is lower and increasing capacity is an efficient process. Further, each channel can be individually employed by using the follower assemblies 430. For example, a single channel can be used even when the spools of all channels are turning together, since the follower assemblies for each channel can be individually controlled to apply pressure via the follower wheels 232 or to release pressure from the follower wheels to allow the spools to slip on a wire at that particular channel.

[0049] Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which these embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Examples

Embodiment Construction

[0023]The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0024]Metal processing such as in the steel industry it is necessary to supply a length of metal wire in precise amounts to obtain the metal composition desired. The metal wire can be powdered alloy cored wire, commonly referred to as “cored wire” or solid metal wire often referred to as “rod” such as aluminum rod or calcium rod. A machine is generally used to supply the metal wire in a manner that is repeatable and consistent in delivering the appropriate amount of wire as determined based on diameter and length. Cored wire is ...

TECHNOLOGICAL FIELD

[0001] Embodiments of the present disclosure relate generally to an apparatus and system for wire feeding, and more particularly, to an apparatus and system for feeding a plurality of wire strands from wire spools into molten metal for the precise formation of alloys.BACKGROUND

[0002] The process of metal making metal and alloys therefrom is centuries old and has involved various processes over the years. More recently, alloy manufacture has involved the introduction of known quantities of solid metal into a molten metal bath to form the alloy. The solid material is generally in the form of a wire or cored wire and is fed in by length, with a defined unit of length corresponding to a predetermined volume of the component being added.

[0003] To facilitate this feeding of a wire, wire feeding machines may be employed, where a wire feeding machine feeds a length of wire from a spool of wire to a molten bath, such as a ladle. Wire feeding is challenging as the wire itself is stiff and often received in coils disposed about spools. The feeding of the wire involves pulling and straightening the wire from the coil, while simultaneously accurately feeding a specific length of the wire to obtain a proper volume of material being added. This is challenging and failure to properly feed the wire can result in alloys of improper compositions, which can be costly to rectify.BRIEF SUMMARY

[0004] A system and apparatus are provided herein for wire feeding, and more particularly, to an apparatus and system for feeding a plurality of wire strands from wire spools into molten metal for the precise formation of alloys. Embodiments include a system for feeding a plurality of wire strands including: a first vertically oriented shaft; a first spool defining a groove and attached to and rotated by the first vertically oriented shaft; a first follower assembly and a third follower assembly, where the first follower assembly is configured to engage the first spool on a first side, where the third follower assembly is configured to engage the first spool on a second side.

[0005] The system of an example embodiment further includes: a second vertically oriented shaft; a second spool defining a groove attached to and rotated by the second vertically oriented shaft; a second follower assembly and a fourth follower assembly, where the second follower assembly is configured to engage the second spool on a first side, and where the fourth follower assembly is configured to engage the second spool on a second side. According to certain embodiments wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction.

[0006] According to some embodiments wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction. The system of some embodiments further includes: a third spool defining a groove and attached to and rotated by the first vertically oriented shaft; a fourth spool defining a groove attached to and rotated by the second vertically oriented shaft; a fifth follower assembly and a sixth follower assembly, where the fifth follower assembly is configured to engage the third spool on a first side, where the sixth follower assembly is configured to engage the fourth spool on a first side; a seventh follower assembly and an eighth follower assembly, where the seventh follower assembly is configured to engage the third spool on a second side, and where the eighth follower assembly is configured to engage the fourth spool on a second side.

[0007] According to some embodiments wire is fed along a third channel, parallel to and offset from the first channel, in response to the wire being captured between the fifth follower assembly and the third spool and the sixth follower assembly and the fourth spool and the third spool and fourth spool rotating in a first direction; and where wire is fed along a fourth channel, parallel to and offset from the first channel, in response to the wire being captured between the seventh follower assembly and the third spool and the eighth follower assembly and the fourth spool and the third spool and fourth spool rotating in a second direction, opposite the first direction.

[0008] According to some embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and where the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The system of some embodiments further includes a cabinet, where the first spool and second spool are disposed within the cabinet, the system further including a motor disposed in a base of the cabinet, where the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft. The system of some embodiments further includes at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool.

[0009] Embodiments provided herein include a module for a wire feeder including: a first spool defining a groove configured to be attached to and rotated by a first vertically oriented shaft; a second spool defining a groove configured to be attached to and rotated by a second vertically oriented shaft, parallel to the first vertically oriented shaft; a first follower assembly and a second follower assembly, where the first follower assembly is configured to engage the first spool on a first side, where the second follower assembly is configured to engage the second spool on a first side; and a third follower assembly and a fourth follower assembly, where the third follower assembly is configured to engage the first spool on a second side, where the fourth follower assembly is configured to engage the second spool on a second side.

[0010] According to certain embodiments wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction. According to certain embodiments wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction.

[0011] According to some embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and where the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The module of some embodiments further includes at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool. Some embodiments described herein include a wire feeder configured to receive within a cabinet the above-described module. According to certain embodiments the cabinet is configured to receive two or more of the above-described module. According to some embodiments the two or more of the above-described modules are stacked vertically along the first vertically oriented shaft and the second vertically oriented shaft.

[0012] Embodiments provided herein include a system for feeding a plurality of wire strands including: a first channel, wherein the first channel passes between a groove of a first spool and a first follower assembly, and between a groove of a second spool and a second follower assembly; a second channel, wherein the second channel passes between the groove of the first spool and a third follower assembly, and between the groove of the second spool and a fourth follower assembly, where the first channel and the second channel are parallel to and offset from one another, where the first spool rotates about a first vertically oriented shaft, where the second spool rotates about a second vertically oriented shaft, and where the first vertically oriented shaft and the second vertically oriented shaft are parallel to and offset from one another.

[0013] According to certain embodiments the first follower assembly includes: a follower wheel; a cylinder actuator; and a lever arm, where the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and wherein the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm. The system of some embodiments further comprises a cabinet, where the first spool and second spool are disposed within the cabinet, the system further including: a motor disposed in a base of the cabinet, wherein the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft.

[0014] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments; further details of which can be seen with reference to the following description and drawings.BRIEF DESCRIPTION OF DRAWINGS

[0015] Having thus described certain embodiments of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0016] FIG. 1 illustrates a complete wire feeder according to an example embodiment of the present disclosure;

[0017] FIG. 2 illustrates the wire feeder of FIG. 1 with the access doors, control panel, and base removed according to an example embodiment of the present disclosure;

[0018] FIG. 3 illustrates the wire feeder of FIG. 2 with the support frame hidden according to an example embodiment of the present disclosure;

[0019] FIG. 4 illustrates a module of a wire feeder and the driving motor according to an example embodiment of the present disclosure;

[0020] FIG. 5 illustrates a top view of a module of a wire feeder according to an example embodiment of the present disclosure;

[0021] FIG. 6 illustrates a top view of one channel of a module of a wire feeder according to an example embodiment of the present disclosure; and

[0022] FIG. 7 illustrates a perspective view of one channel of a module of a wire feeder according to an example embodiment of the present disclosure.DETAILED DESCRIPTION

[0023] The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0024] Metal processing such as in the steel industry it is necessary to supply a length of metal wire in precise amounts to obtain the metal composition desired. The metal wire can be powdered alloy cored wire, commonly referred to as “cored wire” or solid metal wire often referred to as “rod” such as aluminum rod or calcium rod. A machine is generally used to supply the metal wire in a manner that is repeatable and consistent in delivering the appropriate amount of wire as determined based on diameter and length. Cored wire is often used to supply the appropriate components to the metal being formed, such as when producing alloys of steel. Alloys are generally produced using different components to change the properties of the alloy for different use cases. Different alloys of steel are employed in different products to achieve the appropriate strength, durability, machinability, ductility, and corrosiveness among other properties. The use of cored wire enables the production of alloyed steel in a manner that can precisely control the amount of each component of the alloy that is being added.

[0025] The production of cored wire and solid wire is generally performed by compressing metal into an elongate wire form factor. Cored wire typically involves a metal casing compressed about a powdered metal core. Cored wire and solid wire, collectively referred to herein as “wire”, is produced with an elongate body having a consistent diameter such that a length of that cylindrical wire includes a known amount of the metal component—whether cored or solid. This enables the component to be added in the formation of metal based on a length as the length of wire directly corresponds with a volume or mass of that component. Thus, accurate feeding by length using a wire feeder can accurately control a mass of the constituent elements of the wire to be supplied during metal alloy formation.

[0026] In large scale manufacturing, the use of wire involves large coils of wire fed into a furnace or ladle using a wire feeder to provide a precise amount of length of the wire during the metal forming process. Wire feeding machines are programmed to introduce a precise amount of wire to satisfy the requirements of the alloy being formed. This can be challenging as the spools of wire are generally large and exceedingly heavy, such that pulling wire from the spool requires significant force to unwind and straighten wire from the spool.

[0027] The process of metal alloy formation can involve the use of various components that can each be provided via wire via a wire feeding machine. According to embodiments described herein, the wire feeder can include one or more channels, with each channel capable of feeding wire. Each channel is capable of supplying a unique wire component, though high-use components may be fed via multiple channels of the wire feeder described herein.

[0028] FIG. 1 illustrates an example embodiment of a wire feeder 100 as described herein. The wire feeder 100 shown includes a structural frame 105, a base 110, a cabinet 115 with a wire inlet side 120 and a wire exit side 130 of the cabinet. Also shown is the control panel 140 which together with the human-machine interface (HMI) can be used to control the various functions of the wire feeder 100 as described further below. The illustrated embodiment further includes forklift pockets 150 that are integrated into the structural frame 105 to enable mobility of the wire feeder within a facility or between facilities. Access doors 145 are positioned on the front of the cabinet and can be opened to access an interior of the cabinet. Also shown are wire exit guides 135, with each wire exit guide being associated with a respective channel of the wire feeder 100. The wire feeder 100 of the illustrated embodiment is two-sided, with access doors provided on a back side of the wire feeder cabinet 115 in the view shown such that the channels disposed on an opposite side of the cabinet can be accessed as described herein.

[0029] FIG. 2 illustrates the wire feeder 100 of FIG. 1 with the base 110, access doors 145, HMI 147, and control panel 140 removed for ease of understanding. With the access doors 145 removed, the interior of the cabinet 115 is visible. When the access doors 145 are opened by an operator, the operator can access the components shown in FIG. 2 of the cabinet 115. Below the cabinet 115 and within the base 110 is a motor 160. The motor 160 drives an input shaft of the gearbox 165 which translates the rotation of the motor into rotation about a vertical axis, which is used to drive the drive gears described further below.

[0030] FIG. 3 illustrates the wire feeder 100 of FIG. 2, with the structural frame 105 and cabinet 115 removed. As shown, the motor 160 drives an input shaft of the gearbox 165 which is supported on the structural frame by the gearbox bracket 167. The gearbox 165 translates the rotation from the input shaft to rotation about a vertical axis in driving gear 170. Gear 170 drives the belt 180 (or chain) which is engaged with first driven gear 175 and a second driven gear 185. As the first driven gear 175 is driven, it rotates first shaft 190, and as the second driven gear 185 is driven, it rotates the second shaft 195. The first shaft 190 and second shaft 195 can rotate within bearings supported by the cabinet 115 and structural frame 105. The first driven gear 175 and second driven gear 185 are of equal size such that they rotate at the same rate of rotation whereby the rotation of the first shaft 190 and second shaft 195 are synchronized. The motor 160 is capable of rotating in both a forward and reverse direction, which in turn causes the first shaft 190 and second shaft 195 to rotate in both a first direction and a second direction as described further below.

[0031] The wire feeder 100 of FIGS. 1-3 includes eight channels for feeding up to eight spools of wire. Embodiments of the wire feeder described herein include a modular design such that the number of channels can be increased or decreased as needed based on the needs of the end user. The embodiment of FIGS. 1-3 includes four modules stacked vertically along the first shaft 190 and the second shaft 195, with each module employing two channels of the wire feeder 100. A first channel of each module is disposed on a first side of the wire feeder 100 and on a first side of the first spool 210 and second spool 215, while a second channel of the same module is disposed on a second side of the wire feeder, on a second side of the first spool and the second spool as illustrated below.

[0032] FIG. 4 illustrates the wire feeder of FIGS. 1-3 with three of the modules removed to leave a single module for ease of understanding. As shown, the module depicted in FIG. 4 includes a first spool 210 attached to the first shaft 190 and a second spool 215 attached to the second shaft 195. Also shown in FIG. 4 are a first pair of hinge rods 220 and a second pair of hinge rods 225. The hinge rods support follower assemblies 230 that function together with the spools to grab and feed wire through the wire feeder 100.

[0033] FIG. 5 illustrates a top view of a module 200 of embodiments of the wire feeder described herein. The top view illustrates the first spool 210 that rotates about the first shaft 190 and the second spool 215 that rotates about the second shaft 195. There are four follower assemblies 230 on each module, each follower assembly hingedly attached to a respective hinge rod. The hinge rods are supported by the structural frame of the wire feeder as shown in FIGS. 1-3. Also shown in FIG. 5 are the paths for the wire that is fed through the wire feeder. A first path 240 of the first channel is shown by a first dotted line while a second path 250 of the second channel of the illustrated module is shown by another dotted line. These paths are through a respective wire inlet 235, between a first follower assembly 230 and the first spool 210, between a second follower assembly 230 and the second spool 215, and out through the wire exit guides 135. The follower assemblies 230 press the wire into engagement with a respective spool such that the surface of the spool can pull the wire through the wire feeder.

[0034] FIG. 6 illustrates a top view of the partial module 200 with only one wire feed side of the module depicted. As shown, the first spool 210 and the second spool 215 are mounted to the first shaft 190 and the second shaft 195 respectively. The follower assemblies 230 are shown in the open position where a follower wheel 232 is not engaged with a respective spool. The follower assemblies are rotated to the open position about the hinge rods 220. The follower assemblies 230 are rotated to the open position to enable loading of a wire into the wire path through the wire feeder with the first path 240 illustrated in dotted lines.

[0035] To start a wire within the wire feeder as described herein the access doors of the wire feeder shown in FIG. 1 may be moved to the open position to access the inside of the cabinet. The follower assemblies 230 can then be rotated to the open position shown in FIG. 6. With the follower assemblies 230 in the open position shown, a first guide channel 262, a second guide channel 264, and third guide channel 266 can be opened. These channels provide guides for the wire as it passes through the wire feeder and prevents the wire from deviating from the path through the feeder. A wire can be introduced to the wire feeder through the wire inlet 235, through the first guide channel 262, into a groove of the first spool 210, through the second guide channel 264, into a groove of the second spool 215, through the third guide channel 266, and out the wire exit guide 135. The first guide channel 262, second guide channel 264, and third guide channel 266 may each be openable to open a side of the guide channel facing the open access doors of the cabinet to provide an operator access to the guide channels. However, the guide channels do not necessarily need to be opened for feeding of the wire.

[0036] With the wire within the grooves of the first spool 210 and the second spool 215, the follower assemblies 230 can be rotated from the open position shown in FIG. 6 to a closed position as shown in FIG. 5. The follower assemblies can be locked in the closed position, such as using a separate locking mechanism (e.g., a pin) or through other locking mechanisms to hold the follower assemblies in the closed position. This closing of the follower assemblies 230 pinches the wire between the follower assemblies 230 and a respective spool.

[0037] The follower assemblies 230 each include a follower wheel 232 which is what contacts the wire and pushes the wire into the groove of the spool. A cylinder 234, which can be hydraulic, pneumatic, or electric, operates to push against lever arm 236 which supports the follower wheel 232. This pushing or first force imparted by the cylinder 236 drives the wheel 232 in the direction of arrow 238 into the groove of the spool to capture the wire between the follower wheel 232 and the groove of the spool. The groove extends about a circumference of the spool. The groove within the first spool 210 and the groove within the second spool 215 can be curved or in a V-shape, however, the groove includes a textured or ridged surface to help grab and pull wire using the grooves of the spools. When the follower assemblies 230 are in the closed position, and the cylinder 234 presses or biases the lever arm 236, the follower wheel 232 is pressed into the groove which results in the wire being securely grasped by the spool which enables the spool to pull the wire.

[0038] FIG. 7 illustrates a perspective view of the partial module 200 depicting the follower assemblies 230 on a single side of the spools. The follower assemblies 230 of the illustrated embodiment of FIG. 7 are shown in the closed position, with the follower wheel 232 of each follower assembly engaged with a respective spool, such as the first spool 210 and the second spool 215. Also visible in FIG. 7 is a first groove 212 of the first spool and a second groove 217 of the second spool 215. In the illustrated closed position of the follower assemblies, the cylinder 234 drives the lever arm 236 to press the follower wheel into the groove of the respective spool, thereby driving the wire within the groove into engagement with the textured or ridged surface within the groove. This cooperation ensures that the wire captured between the follower wheel 232 and the groove of the spool remains engaged with the spool and does not slip as the spool pulls the wire through the wire feeder of embodiments described herein.

[0039] It is important for embodiments of the wire feeder of example embodiments to securely grip the wire being fed through the wire feeder. This ensures that the spool does not slip relative to the wire. With the wire being securely gripped between a follower wheel 232 and a groove of the first spool 210 or the second spool 215 enables accurate feeding of the wire as each rotation or portion thereof for a spool will translate into a length of wire being fed from the wire feeder. If the wire were to slip within the groove, accurate wire mass feeding would be compromised since the length of wire fed would not correspond to a degree of rotation of a spool.

[0040] Wire feeding in example embodiments often employs a spool of wire as a source from which the wire feeder pulls the wire. Alloy wire is relatively thick in diameter and thus a spool of such wire is resistant to straightening. Pulling such a wire through a wire feeder requires significant force and a solid grasp on the wire as it is pulled from the spool and straightened. Embodiments described herein provide such solid grip and the motor driving the first spool 210 and the second spool 215 provides sufficient power to pull the wire from the spool and feed the wire through the wire exit 135.

[0041] In addition to the efficient and effective wire feeding described above, embodiments are uniquely configured to be modular in such a way as to enable multiple channels of the wire feeder to be implemented as needed. Referring back to the module 200 depicted in FIG. 5, the module 200 includes the first path 240 shown by the first dotted line and the second path 250 shown by the second dotted line. Wire is not fed along the first path 240 and the second path 250 at the same time. Conversely, wire will be fed from one path or the other, as the first spool 210 and the second spool 215 rotate in different directions based on which wire feed path is being used. To feed wire along the first path 240 and not the second path 250, the follower assemblies 230 associated with the second path 250 may be disengaged. The follower assemblies can be disengaged, for example, by retracting cylinder 234 which in turn pulls on lever arm 236 (applying a second force) which pulls the follower wheel 232 away from the groove of the spool. Optionally, the follower assemblies of a path not being used may be moved to the open position shown in FIG. 6 or a partially open position as needed. If there is a wire along the path not being used, disengagement of the follower assemblies 230 would result in the wire failing to be grasped by the respective spool, such that rotation direction of the spool does not impact the wire along that path.

[0042] While embodiments described above describe a pushing force of the cylinder 234 driving the follower wheel 232 into engagement with the cylinder and a pulling force of the cylinder pulling the follower wheel 232 away from engagement with the spool, such a cylinder can be arranged in a different orientation in which a first force, be it a pushing force or a pulling force, presses the follower wheel 232 into engagement with the spool while a second force, be it a pushing force or a pulling force, moves the follower wheel 232 out of engagement with the spool.

[0043] To feed wire along the first path 240 the first spool 210 and the second spool 215 would rotate in a counterclockwise direction, pulling the wire toward the wire exit 135 while the follower assemblies 230 of the first path 240 are engaged and while follower assemblies 230 of the second path 250. To feed wire along the second path 250, the first spool 210 and the second spool 215 would rotate in the clockwise direction while the follower assemblies 230 along the second path 250 are engaged and the follower assemblies along the first path 240 are disengaged.

[0044] Access to each wire feed channel is a key benefit of example embodiments described herein. The illustration of FIG. 2 demonstrates the accessible nature of the modules of the wire feeder 100 of example embodiments described herein. The modules allow for expansion of capacity of the wire feeder 100 by adding additional wire feed channels. These are added in a vertical arrangement, with four modules visible in the embodiment of FIG. 2, each module including two wire feed channels. Arranging these modules vertically provides access to each wire feed channel through access doors on the front and the rear. Each wire feed channel of a side is accessible without requiring reaching over other wire feed channels, and each wire feed channel is readily accessible to address obstructions, feeding of new wire, and maintenance of the components of each wire feed channel. This arrangement is distinct from any previous wire feeders.

[0045] Embodiments described herein are modular in that multiple wire feed paths may be employed beyond the two wire feed paths per module. The configuration of embodiments described herein provide a unique advantage over prior wire feeders as the spools are arranged to rotate about vertical axes, which enables additional modules to be incorporated without altering a footprint of the wire feeder. Additional modules stack vertically atop other modules to form a stack of modules sufficient to satisfy the needs of a user. Maintaining the same footprint with increased wire feeding capacity allows the use of more wire feeding paths within the same floorspace of a facility. Further, additional motors to drive the wire feeding are not necessary, since the motor and gearbox positioned beneath the modules as depicted in FIGS. 2-4 is capable of driving the spools of each module.

[0046] Manufacturers of steel alloys require substantial quantities of wire. Wire is now mass produced for alloy manufacture at scale to satisfy the needs of the industry. Wire is produced in long lengths of wire that is typically wound about a reel for transportation, distribution, and consumption. However, working with such spools of wire is cumbersome, particularly in the mass production of steel where accurate alloy production requires precise lengths of cored metal alloy wires to be added to liquid metal, such as into a ladle prior to casting.

[0047] Embodiments described herein provide a modular wire feeder that can scale with the needs of a facility while being capable of accurately feeding precise lengths of wire during metal making even on a large industrial scale.

[0048] Embodiments of the wire feeder described herein are not only modular and hence scalable, but they are also more easily maintained than existing wire feeders. With the module configuration and each module including wire channels readily accessible through access doors without requiring reach or crossing the path of another channel. Further, modules described herein are each driven by a single motor, such that the cost of embodiments described herein is lower and increasing capacity is an efficient process. Further, each channel can be individually employed by using the follower assemblies 430. For example, a single channel can be used even when the spools of all channels are turning together, since the follower assemblies for each channel can be individually controlled to apply pressure via the follower wheels 232 or to release pressure from the follower wheels to allow the spools to slip on a wire at that particular channel.

[0049] Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which these embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Examples

Embodiment Construction

[0023]The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

[0024]Metal processing such as in the steel industry it is necessary to supply a length of metal wire in precise amounts to obtain the metal composition desired. The metal wire can be powdered alloy cored wire, commonly referred to as “cored wire” or solid metal wire often referred to as “rod” such as aluminum rod or calcium rod. A machine is generally used to supply the metal wire in a manner that is repeatable and consistent in delivering the appropriate amount of wire as determined based on diameter and length. Cored wire is ...

Claims

1. A system for feeding a plurality of wire strands comprising:a first vertically oriented shaft;a first spool defining a groove and attached to and rotated by the first vertically oriented shaft; anda first follower assembly and a third follower assembly, wherein the first follower assembly is configured to engage the first spool on a first side, wherein the third follower assembly is configured to engage the first spool on a second side.

2. The system of claim 1, further comprising:a second vertically oriented shaft;a second spool defining a groove attached to and rotated by the second vertically oriented shaft;a second follower assembly and a fourth follower assembly, wherein the second follower assembly is configured to engage the second spool on a first side, wherein the fourth follower assembly is configured to engage the second spool on a second side.

3. The system according to claim 2, wherein wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction.

4. The system according to claim 3, wherein wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction.

5. The system of claim 4, further comprising:a third spool defining a groove and attached to and rotated by the first vertically orienteda fourth spool defining a groove attached to and rotated by the second vertically oriented shaft;a fifth follower assembly and a sixth follower assembly, wherein the fifth follower assembly is configured to engage the third spool on a first side, wherein the sixth follower assembly is configured to engage the fourth spool on a first side;a seventh follower assembly and an eighth follower assembly, wherein the seventh follower assembly is configured to engage the third spool on a second side, wherein the eighth follower assembly is configured to engage the fourth spool on a second side.

6. The system of claim 5, wherein wire is fed along a third channel, parallel to and offset from the first channel, in response to the wire being captured between the fifth follower assembly and the third spool and the sixth follower assembly and the fourth spool and the third spool and fourth spool rotating in a first direction; andwherein wire is fed along a fourth channel, parallel to and offset from the first channel, in response to the wire being captured between the seventh follower assembly and the third spool and the eighth follower assembly and the fourth spool and the third spool and fourth spool rotating in a second direction, opposite the first direction.

7. The system according to claim 1, wherein the first follower assembly comprises:a follower wheel;a cylinder actuator; anda lever arm, wherein the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and wherein the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm.

8. The system according to claim 2, further comprising a cabinet, wherein the first spool and second spool are disposed within the cabinet, the system further comprising:a motor disposed in a base of the cabinet, wherein the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft.

9. The system of claim 2, further comprising at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool.

10. A module for a wire feeder comprising:a first spool defining a groove configured to be attached to and rotated by a first vertically oriented shaft;a second spool defining a groove configured to be attached to and rotated by a second vertically oriented shaft, parallel to the first vertically oriented shaft;a first follower assembly and a second follower assembly, wherein the first follower assembly is configured to engage the first spool on a first side, wherein the second follower assembly is configured to engage the second spool on a first side; anda third follower assembly and a fourth follower assembly, wherein the third follower assembly is configured to engage the first spool on a second side, wherein the fourth follower assembly is configured to engage the second spool on a second side.

11. The module according to claim 10, wherein wire is fed in along a first channel in response to the wire being captured between the first follower assembly and the first spool and the second follower assembly and the second spool and the first spool and second spool rotating in a first direction.

12. The module according to claim 11, wherein wire is fed along a second channel, parallel to and offset from the first channel, in response to the wire being captured between the third follower assembly and the first spool and the fourth follower assembly and the second spool and the first spool and second spool rotating in a second direction, opposite the first direction.

13. The module according to claim 10, wherein the first follower assembly comprises:a follower wheel;a cylinder actuator; anda lever arm, wherein the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and wherein the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm.

14. The module of claim 10, further comprising at least one guide channel disposed between the first spool and the second spool on the first side of the first spool and the second spool, and at least one guide channel disposed between the first spool and the second spool on the second side of the first spool and the second spool.

15. A wire feeder configured to receive within a cabinet the module of claim 10.

16. The wire feeder of claim 15, wherein the cabinet is configured to receive two or more of the modules.

17. The wire feeder of claim 16, wherein the two or more of the modules are stacked vertically along the first vertically oriented shaft and the second vertically oriented shaft.

18. A system for feeding a plurality of wire strands comprising:a first channel, wherein the first channel passes between a groove of a first spool and a first follower assembly, and between a groove of a second spool and a second follower assembly;a second channel, wherein the second channel passes between the groove of the first spool and a third follower assembly, and between the groove of the second spool and a fourth follower assembly,wherein the first channel and the second channel are parallel to and offset from one another,wherein the first spool rotates about a first vertically oriented shaft, wherein the second spool rotates about a second vertically oriented shaft, and wherein the first vertically oriented shaft and the second vertically oriented shaft are parallel to and offset from one another.

19. The system according to claim 18, wherein the first follower assembly comprises:a follower wheel;a cylinder actuator; anda lever arm, wherein the lever arm biases the follower wheel into engagement with the first spool in response to the cylinder actuator applying a first force the lever arm, and wherein the lever arm pulls the follower wheel away from the first spool in response to the cylinder actuator applying a second force the lever arm.

20. The system according to claim 19, further comprising a cabinet, wherein the first spool and second spool are disposed within the cabinet, the system further comprising:a motor disposed in a base of the cabinet, wherein the motor drives rotation of the first vertically oriented shaft and the second vertically oriented shaft.

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