Repositionable gear box and motor

Abstract

A repositionable gearbox and motor that can be used with a mechanism, such as a wire feeder. The motor can be activated or operated to drive one or more gears in the gearbox, which in turn drive one or more components of a mechanism that is operably coupled to the gearbox. The gearbox and motor can drive the component of the mechanism when the gearbox and the motor are in a first position or orientation. In addition, the gearbox and motor can drive the component of the mechanism when the gearbox and the motor are in a second position or orientation that is different from the first position or orientation. The repositionable gearbox includes a locking mechanism that retains the gearbox in a particular position or orientation relative to the mechanism it is actuating.

Description

REPOSITIONABLE GEAR BOX AND MOTORCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent App. No. 63 / 625,606, filed January 26, 2024, entitled “Repositionable Gear Box and Motor”, the entire disclosure of which is incorporated by reference herein in its entirety.FIELD OF THE DISCLOSURE

[0002] The present invention relates to a repositionable gear box and motor, and more specifically, to a repositionable gear box and motor that can be used to drive a wire feeder mechanism.BACKGROUND

[0003] Some uses of mechanical devices may be in small areas or difficult to reach spaces. Some mechanical devices may have one or more components that are driven by a motor or drive system. However, sometimes such small areas do not have the capacity to accommodate a motor or drive system. One exemplary mechanical device is a wire feeder mechanism, which is used to advance wire.

[0004] Thus, there is a need for a system that can be repositioned or reconfigured to be used in difficult or small spaces. There is also a need for a repositionable gearbox and motor system that can be adjusted to have a particular position or orientation, depending on the desired application.SUMMARY

[0005] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

[0006] In one embodiment, the system according to the present invention includes a repositionable gearbox and motor. The motor can be activated or operated to drive one or more gears in the gearbox, which in turn drive one or more components of a mechanism that is operablycoupled to the gearbox. The gearbox and motor can drive the component of the mechanism when the gearbox and the motor are in a first position or orientation. In addition, the gearbox and motor can drive the component of the mechanism when the gearbox and the motor are in a second position or orientation that is different from the first position or orientation. The repositionable gearbox includes a locking mechanism that retains the gearbox in a particular position or orientation relative to the mechanism it is actuating.

[0007] In one implementation, the mechanism can be a wire feeder mechanism with at least one driven roller, and the gearbox and motor are actuatable to drive the roller of the wire feeder mechanism.

[0008] In one embodiment according to the present disclosure, a repositionable drive system for use with a mechanism comprises a gearbox containing at least one gear, a motor coupled to the gearbox, the motor being operably connected to the at least one gear to drive the at least one gear, and a locking assembly engageable with the gearbox, wherein the gearbox and the motor are disposable in a first position relative to the mechanism and are disposable in a second position relative to the mechanism, the gearbox and the motor having a different orientation relative to the mechanism when the gearbox and the motor are in the second position relative to when the gearbox and the motor are in the first position, the locking assembly being configured to secure the gearbox and the motor in either of the first position or the second position.

[0009] In an alternative embodiment, the motor can drive the at least one gear when the gearbox and the motor are in the first position and when the gearbox and the motor are in the second position.

[0010] In another embodiment, the locking assembly has an unlocked configuration in which the gearbox and the motor can rotate about an axis between the first position and the second position, and the locking assembly has a locked configuration in which the gearbox and the motor are prevented from rotating about the axis.

[0011] In yet another embodiment, the mechanism is a wire feeder, and the gearbox and the motor can be disposed in a plurality of positions relative to the wire feeder.

[0012] In an alternative embodiment, the locking assembly includes a first locking lever and a second locking lever, and each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position.

[0013] In one embodiment, at least one of the first locking lever and the second locking lever is configured to engage a portion of the mechanism to retain the gearbox and the motor in a position relative to the mechanism.

[0014] In another embodiment, the first locking lever includes first locking portion and the second locking lever includes a second locking portion, the second locking portion being engageable with the first locking portion to couple the first locking lever to the second locking lever.

[0015] In yet another embodiment, the first locking portion includes a first locking component, the second locking portion includes a second locking component and a pair of walls defining a receptacle therebetween, the receptacle being configured to receive the first locking component, and the first locking component and the second locking component are proximate to each other when the first locking component is in the receptacle.

[0016] In an alternative embodiment, the first locking component includes a first hole, the second locking component includes a second hole, and the second hole is aligned with the first hole when the first locking component is in the receptacle.

[0017] In one embodiment, the pair of walls includes a first wall and a second wall spaced apart from the first wall, each of the first wall and the second wall has a curved configuration, and the receptacle between the first wall and the second wall has a similar shape to the first locking component.

[0018] In another embodiment, the first wall has a first inner surface, the second wall has a second inner surface, and the first locking component has an outer surface, and the outer surface of the first locking component engaging the first inner surface of the first wall and the second inner surface of the second wall when the first locking component is located in the receptacle.

[0019] In another implementation according to the present disclosure, a repositionable drive system for use with a wire feeder comprises a gearbox containing at least one gear, a motor coupled to the gearbox, the motor being operably connected to the at least one gear to drive the at least one gear, and a locking assembly engageable with the gearbox, wherein the gearbox and the motor are disposable in a plurality of different positions relative to the wire feeder, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in a different position, the locking assembly being configured to secure the gearbox and the motor in any one of the plurality of different positions.

[0020] In yet another embodiment, the plurality of different positions includes a first position relative to the wire feeder and a second position relative to the wire feeder, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in the second position relative to when the gearbox and the motor are in the first position.

[0021] In an alternative embodiment, the motor can drive the at least one gear when the gearbox and the motor are in the first position and when the gearbox and the motor are in the second position.

[0022] In another embodiment, the locking assembly includes a first locking lever and a second locking lever, and each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position.

[0023] In yet another embodiment, the first locking lever includes first locking portion and the second locking lever includes a second locking portion, and the second locking portion is engageable with the first locking portion to couple the first locking lever to the second locking lever.

[0024] In one embodiment, the first locking portion includes a first locking component, the second locking portion includes a second locking component and a pair of walls defining a receptacle therebetween, the receptacle being configured to receive the first locking component, and the first locking component and the second locking component are proximate to each other when the first locking component is in the receptacle.

[0025] In another implementation according to the present disclosure, a repositionable drive system for use with a wire feeder comprises a gearbox containing at least one gear, a motor operably connected to the at least one gear to drive the at least one gear, and a locking assembly engageable with the gearbox, the locking assembly including a first pivotally mounted locking lever and a second pivotally mounted locking lever, wherein the gearbox and the motor are disposable in a first position relative to the wire feeder and in a second position relative to the wire feeder, the second position being different from the first position, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in the first position and in the second position, the locking assembly being configured to secure the gearbox and the motor relative to the wire feeder.

[0026] In an alternative embodiment, the motor is configured to drive the at least one gear when the gearbox and the motor are in the first position and also when the gearbox and the motor are in the second position.

[0027] In another embodiment, the locking assembly includes a first locking lever and a second locking lever, each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position, the first locking lever includes first locking portion and the second locking lever includes a second locking portion, and the second locking portion is engageable with the first locking portion to couple the first locking lever to the second locking lever.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] By way of example, a specific embodiment of the disclosed invention is described with reference to the accompanying drawings.

[0029] FIG. 1 is a schematic block diagram that illustrates an embodiment of a system that includes a repositionable gearbox and motor according to the present invention.

[0030] FIG. 2 is an exploded side view of an embodiment of a system that includes a repositionable gearbox and motor according to the present invention.

[0031] FIG. 3 is an end view the system illustrated in FIG. 2 showing different positions and orientations of the repositionable gearbox and motor.

[0032] FIG. 4 is a side view of the system illustrated in FIG. 2 with the repositionable gearbox and motor in a first position or orientation.

[0033] FIG. 5 is a side view of the system illustrated in FIG. 4 with the repositionable gearbox and motor in a second position or orientation.

[0034] FIG. 6 is a side view of the gearbox and motor and the wire feeder mechanism illustrated in FIG. 2 coupled together.

[0035] FIG. 7 is an end view of the repositionable gearbox with its locking levers in their opened positions.

[0036] FIG. 8 is an end view of the repositionable gearbox with its locking levers in their locked positions.

[0037] FIG. 9 is a top perspective view of an embodiment of a system including a repositionable gearbox and motor according to the present invention coupled to a wire feeder mechanism.

[0038] FIG. 10 is another top perspective view of the system illustrated in FIG. 9.

[0039] FIG. 11 is a side view of the system illustrated in FIG. 9.

[0040] FIG. 12 is an exploded side view of several of the components of the system illustrated in FIG. 9.

[0041] FIG. 13 is another exploded perspective view of some of the components illustrated in FIG. 12.

[0042] FIG. 14 is a perspective view of an embodiment of a wall that can be located between the repositionable gearbox and the wire feeder mechanism.

[0043] FIG. 15 is a perspective view of an embodiment of the locking levers of the repositionable gearbox.

[0044] FIG. 16 is another perspective view of the locking levers illustrated in FIG. 15.

[0045] FIG. 17 is another perspective view of the locking levers illustrated in FIG. 15.

[0046] FIG. 18 is a perspective view of the repositionable gearbox illustrated in FIG. 9 showing the locking levers in their locked positions.

[0047] FIG. 19 is a perspective view of the wall illustrated in FIG. 14 with the locking levers illustrated in FIG. 15 in their locked positions.

[0048] FIG. 20 is an end view of another embodiment of a repositionable gearbox with its locking levers in their opened positions.

[0049] FIG. 21 is an end view of the repositionable gearbox illustrated in FIG. 20 with its locking levers in their locked positions.

[0050] FIG. 22 is an end view of another embodiment of a repositionable gearbox according to the present disclosure.

[0051] FIG. 23 is an end view of the repositionable gearbox illustrated in FIG. 22 with a portion of the gearbox housing removed.

[0052] FIG. 24 is a close-up end view of some components of the repositionable gearbox illustrated in FIG. 22 with its locking levers in their opened positions.

[0053] FIG. 25 is a perspective view of the locking levers illustrated in FIG. 24.

[0054] FIG. 26 is a side view of the locking levers illustrated in FIG. 25.

[0055] FIG. 27 is a botom view of the locking levers illustrated in FIG. 25.DETAILED DESCRIPTION

[0056] The present invention relates to a system that includes a wire feeder and a repositionable gearbox and motor. The wire feeder can be any type of wire feeder that can advance wire. Some exemplary wire feeder mechanisms are disclosed in U.S. Patent Application Publication No. 2021 / 0245288 published August 12, 2021 and entitled “Wire Feeder”, the entire disclose of which is incorporated herein by reference in its entirety for all purposes.

[0057] The present invention also includes a repositionable gearbox and motor that can be moved by a manufacturer or supplier to a desired position or orientation, depending on the application and the space available for the wire feeder mechanism. The repositionable gearbox and motor can be placed into one position relative to the wire feeder mechanism and secured in that position. When a manufacturer or supplier wants to reposition the gearbox and motor in different positions for different applications, feeder layouts, products, etc., the locking mechanism holding the gearbox and motor in place can be unlocked and the gearbox and motor rotated about an axis to a different position. When the desired new position or orientation of the gearbox and motor is reached, the manufacturer or supplier can activate or lock the locking mechanism to secure the gearbox and motor in that new position. This process can be repeated by a manufacturer or supplier to reposition the gearbox and motor in different positions. The rotational gearbox makes the entire unit more versatile for use in different environments.

[0058] In one embodiment, the repositionable gearbox and motor can spin or rotate 360° relative to a wire feeder mechanism to which it is coupled, while staying connected to the wire feeder mechanism. As mentioned above, the gearbox and motor can be secured or locked in a position relative to the feeder mechanism, and they are rotatable only when they are unlocked.

[0059] Referring to FIG. 1, a schematic diagram of an embodiment of a system that includes a wire feeder and a gearbox and motor component is illustrated. In this embodiment, the system includes a wire feeder 10 that is connected to the gearbox and motor component 20. The gearbox and motor component 20 is movable between a first position or orientation 22 and a second position or orientation 24 that is different from the first position or orientation 22. The gearbox and motor component 20 can be moved between positions 22 and 24 when the gearbox and motor20 are unlocked relative to the wire feeder 10. Even though the gearbox and motor 20 are unlocked, they can remain coupled to the wire feeder 10.

[0060] Turning to FIG. 2, an embodiment of a system that includes a wire feeder and a repositionable gearbox and motor component is illustrated. In this embodiment, the wire feeder 100 includes a body 102 and a pair of rollers 104 and 106 that are rotatably mounted on the body 102. At least one of the rollers 104 and 106 is driven to advance an elongate member, such as a wire.

[0061] The wire feeder 100 also includes a mounting portion 110 that has an outer perimeter 112 with teeth 114 located around the outer perimeter 112. The outer perimeter 112 also includes a slot 116 formed therein. In one implementation, the slot 116 extends continuously around the perimeter of the outer perimeter 112. As discussed in greater detail below, the slot 116 receives portions of locking levers of the gearbox when the locking levers are moved to their locked or closed positions.

[0062] FIG. 2 also illustrates a wall 150 to which the wire feeder 100 is mounted. The wall 150 has a first side 152 and a second side 154 opposite to first side 152. Several fasteners 156 extend outwardly from the first side 152 of the wall 150. The fasteners 156 engage the wire feeder 100 to secure and mount the wire feeder to the wall 150. The wall 150 also includes an opening formed therein through which the mounting portion 110 of the wire feeder 100 is inserted. It is to be understood that the wall 150 is exemplary of a structure, such as a wall, to which the wire feeder 100 can be coupled. The wall 150 can have any size or shape provided that it can sufficiently provide support for the wire feeder 100 and the gearbox 200.

[0063] The gearbox 200 and the motor 300 are coupled together and are located on an opposite side of wall 150 from the wire feeder 100. In this embodiment, the gearbox 200 includes a body 210 to which the motor 300 is secured, and the body 210 includes a mounting portion 230 that is coupled to the mounting portion 110 of the wire feeder mechanism 100. The gearbox 200 and the motor 300 can be repositioned or reoriented relative to the wire feeder 100. In one implementation, the gearbox 200 and the motor 300 can be rotated 360° around an axis relative to the wire feeder mechanism 100.

[0064] Turning to FIG. 3, the wire feeder 100 and wall 150 are shown. In addition, the gearbox 200 and the motor 300 are illustrated, and multiple positions or orientations of the gearbox 200 and the motor 300 are shown. The gearbox 200 and motor 300 are illustrated in solid lines in afirst orientation 220 and are illustrated in dashed lines in a second orientation 222. The gearbox 200 has body 210 that has a longitudinal axis 212. The longitudinal axis 212 extends through a pivot point 214 about which the gearbox 200 and the motor 300 rotate. An axle defining a pivot axis is located at the pivot point 214. In FIG. 3, the path about which the gearbox 200 can travel as illustrated by circle 216. When the gearbox 200 is not locked to the wire feeder 100, the gearbox 200 can move from its first position 220 to its second position 222, which is illustrated in dashed lines. When the gearbox 200 moves to position 222 from position 220, the longitudinal axis 212 of the gearbox 200 rotates about pivot point 214. In addition, when not locked in a position, the gearbox 200 can be rotated to any position in a full 360 degree circle.

[0065] Referring to FIGS. 4 and 5, different side views of the wire feeder 100, the gearbox 200, and the motor 300 are illustrated. Turning initially to FIG. 4, the mounting portion 110 of the wire feeder 100 extends through an opening 158 that is formed in the wall 150. The housing or body 210 of the gearbox 200 has the motor 300 coupled thereto. The gearbox 200 can be moved along the direction of arrow “A” toward the wall 150 and the wire feeder mechanism 100 so they can be coupled together. The mounting portion 230 of the gearbox 200 includes a central member 236 and a projecting portion 240, having a cylindrical configuration, that extend outwardly away from the body of the gearbox 200. The projecting portion 240 engages with the mounting portion 110 of the wire feeder mechanism 100, and is used to secure the gearbox 200 in place.

[0066] The gearbox 200 and the motor 300 are shown in one position 222 in FIG. 4 and in a different position 220 in FIG. 5. The gearbox 200 and the motor 300 are moved between position 220 and position 222, and also moved beyond that range, by rotating the gearbox 200 around the axis 225 along the direction of arrow “B”, or alternatively, in a direction opposite to arrow “B” When the gearbox 200 and the motor 300 are in their desired position or orientation, they can be locked in place as described in greater detail below.

[0067] In FIG. 6, the gearbox 200 is illustrated as having been coupled to the wire feeder mechanism 100. One of the locking levers of the gearbox 200 (locking lever 280 in particular) is shown in this side view.

[0068] Turning to FIG. 7, an end view of the gearbox 200 with its locking levers in their opened or unlocked positions is illustrated. The body 210 of the gearbox 200 includes a pair of mounting posts or couplers 232 and 234 that extend away from the outer surface of the body 210. The central member 236 has a notch 238 formed therein into which a tab 239 extends. The tab239 and notch 238 engagement results in the proper rotation of the gearbox 200 and its components about axis 225, which extends through central member 236.

[0069] Details and various features of the mounting portion 230 of the gearbox 200 are also illustrated in FIG. 7 as well. The mounting portion 230 is used to mount the gearbox 200 to the wire feeder mechanism 100. The mounting portion 230 also has the previously mentioned cylindrically shaped projecting portion 240 which has an outer surface 242 with outwardly extending ridges 244 and 246 on opposite sides thereof. The projecting portion 240 also has an inner surface 248 that has opposing sets of teeth 250 and 252 located thereon. The teeth 250 and 252 engage teeth on the collar of the wire feeder mechanism and are self-locking due to the engagement.

[0070] The gearbox 200 includes a locking assembly 255 that includes a locking lever 270 that is rotatably mounted on post 232 and a locking lever 280 that is rotatably mounted on post 234. In this example implementation, locking lever 280 is similarly structured to, and is a mirror image of, locking lever 270. Locking lever 270 includes a body 271 with an end 272 and another end 273 opposite to end 272. The body 271 includes an opening 274 that receives post 232 when the locking lever 270 is mounted or coupled to the gearbox 200. The body 271 has an inner surface that has a projecting arc portion 275 extending therefrom. Proximate to end 273, an engagement tab 276 extends from the body 271. Similarly, locking lever 280 includes a body 281 with an end 282 and another end 283 opposite to end 282. The body 281 includes an opening 284 that receives post 234 when the locking lever 280 is mounted or coupled to the gearbox 200. The body 281 has an inner surface that has a projecting arc portion 285 extending therefrom. Proximate to end 283, an engagement tab 286 extends from the body 281.

[0071] In FIG. 7, the locking levers 270 and 280 are illustrated in their opened or unlocked positions 290. Locking lever 270 has been moved along the direction of arrow “C” away from lever 280. Similarly, locking lever 280 has been moved along the direction of arrow “D” away from lever 270. When the locking levers 270 and 280 are in their opened positions 290, the gearbox 200 and motor 300 can be rotated to a different position relative to the wire feeder mechanism 100.

[0072] Turning to FIG. 8, the locking levers 270 and 280 are illustrated in their locked or closed positions 292. Locking lever 270 has been rotated about post 232 along the direction of arrow “E” to its illustrated position. Similarly, locking lever 280 has been rotated about post 234along the direction of arrow “F” to its illustrated position. In these closed positions 292, the ends 273 and 283 of the locking levers 270 and 280, respectively, are located proximate to each other. In one embodiment, the ends 273 and 283 may have openings or holes formed therein through which a fastener or coupler may be inserted to secure the ends 273 and 283 together so that the levers 270 and 280 do not rotate or move. Some exemplary fasteners or couplers may include an elongate member such as a zip tie or other tying mechanism, a bolt and nut combination, or any similar structure.

[0073] The projecting arc portion 275 on the body 271 of locking lever 270 extends into and through a slot formed in the wall of the projecting portion 240. Similarly, the projecting arc portion 285 on the body 281 and locking lever 280 extends into and through another slot formed in the wall of the projecting portion 240. As shown in FIG. 8, the projecting arc portions 275 and 285 extend into the cavity 241 defined by the projecting portion 240, which enables the projecting arc portions 275 and 285 to engage and grip the slot 116 formed in the outer perimeter 112 of the coupling portion 110 of the wire feeder mechanism 100. Thus, when the locking levers 270 and 280 are in their locked positions 292, the projecting arc portions 275 and 285 engage the slot 116 to secure the gearbox 200 in its position relative to the wall 150 and the wire feeder mechanism 100.

[0074] In general, the repositioning or reorienting of the gearbox 200 and motor 300 is done at assembly in a factory by a product supplier. The ability to reposition the gearbox and motor allows them to be universally used, thereby permitting the same feeder mechanism, gearbox and motor to be used with various different products, for different applications, and in different environments because of the universal fit. When a manufacturer or supplier wants to reposition or reorient the gearbox 200 and motor 300, the manufacturer or supplier can remove any fastening or coupling mechanism that is holding the ends 273 and 283 of the locking levers 270 and 280 together. Once that mechanism is removed, the locking levers 270 and 280 can be rotated along the directions of arrows “C” and “D” in FIG. 7 to their opened positions 290. Once the locking levers 270 and 280 are in their opened positions 290, the gearbox 200 and motor 300 can be rotated to any desired position or orientation.

[0075] Turning to FIGS. 9- 19, an embodiment of a system according to the present invention is illustrated. In this embodiment, referring initially to FIG. 9, the system 400 includes a wire feeder mechanism 500 that is located on one side 602 of a wall 600. The wire feeder mechanism500 includes a pair of rotating members or rollers 510 and 512 and several ports (only port 520 is illustrated) through which an elongate member, such as a wire (not shown), is drawn into or pushed out. A gearbox 800 is located on the opposite side of the wall 600 from the wire feeder mechanism 500. The gearbox 800 includes a housing or body 810 to which a motor 700 is coupled. The motor 700 can be actuated or powered to drive one or more gears in the gearbox 800 to in turn drive one or both of the rollers 510 and 512 of the wire feeder mechanism 500.

[0076] Turning to FIG. 10, another perspective view of the system 400 is illustrated. The gearbox 800 and the motor 700 are located on side 604 of the wall 600. Turning to FIG. 11, a side view of the system 400 is illustrated. In this view, a locking lever 860 of the gearbox is shown, which is described in greater detail below.

[0077] Referring to FIG. 12, an exploded perspective view of several components of the system 400 is illustrated. In this embodiment, the gearbox 800 includes housing portion 812 and housing portion 814 that are coupled together to form the body 810 of the gearbox 800. The motor 700 includes a housing 710 that has several mounting posts 712 that secure the housing 710 of the motor 700 to housing portion 814. The motor 700 includes an output shaft 720 that has an output gear 730 mounted thereon.

[0078] Gearbox housing portion 812 has a collar or projecting portion 820 that extends outwardly therefrom. The projecting portion 820 has an outer surface 822 with a pair of slots formed in opposite sides thereof. In FIG. 12, only slot 830 is formed in the wall of the projecting portion 820 and extending from the outer surface 822 to the inner surface. The gearbox 800 also includes a rotatably mounted gear 850 that has a large diameter gear portion 852 with teeth that engage the teeth on gear 730. Gear 850 also has a small diameter gear portion 854 that rotates with gear portion 852 and that drives another gear to cause the rotating members to rotate.

[0079] In this embodiment, gearbox 800 includes locking levers 860 and 880 pivotally or rotatably mounted to housing portion 812. The specific features and structures of locking levers 860 and 880 are described below relative to FIGS. 15-18.

[0080] It is to be noted that the wall 600 in the system 400 is not illustrated in FIG. 12 for ease of reference only. Only some of the components of the wire feeder mechanism 500 are shown in FIG. 12. In particular, the wire feeder mechanism 500 includes a body 530 that has a surface 532 from which a collar or coupling portion 540 extends. The coupling portion 540 has an outer surface 542 that have spaced apart teeth 544 formed therein around the perimeter of the coupling portion540. In addition, a groove 546 is continuously formed around the perimeter as well. The coupling portion 540 also includes an inner surface 548.

[0081] Referring to FIG. 13, a perspective view of a few of the components illustrated in FIG. 12 is shown. The wire feeder mechanism body 530 with its collar or coupling portion 540 and its groove 546 are illustrated, along with locking levers 860 and 880. The collar 820 of the gearbox housing portion 812 is shown. The collar 820 has an inner surface 824 that has two opposing sets of teeth 826 and 828 formed therein. The slots 830 and 832 that extend from the outer surface 822 through the wall to the inner surface 824 are located on opposite sides of the collar 820 from each other.

[0082] An embodiment of a wall according to the present invention is illustrated in FIG. 14. In this embodiment, the wall 600 includes an opening 610 formed therein that extends from side 604 to side 602 of the wall 600. The wall 600 also includes several mounting posts 620 that extend from side 604.

[0083] Referring to FIGS. 15-17, different perspective views of locking levers 860 and 880 are illustrated. Locking lever 860 includes a body 861 that extends from one end 862 to an opposite end 863. End 862 has a mounting hole 864 formed therein that allows the locking lever 860 to be rotatably mounted to the gearbox 800. The body 861 has an inner surface 866 with a projecting arc portion 868 that extends inwardly. The body 861 also includes a stepped portion 865 and a varying height outer wall 867.

[0084] Locking lever 860 also includes a locking portion 874 with a locking hole 876 formed therein. The locking hole 876 can receive a fastener or coupler that is used to connect the free ends of locking levers 860 and 880 together to hold them in place. Locking lever 860 also includes a coupler 870 that extends from end 863 and that has a tooth or tab 872 formed thereon (see FIG. 17). The tooth or tab 872 is sized to engage a notch formed on locking lever 880, as described in detail below.

[0085] Locking lever 880 includes a body 881 that extends from one end 882 to an opposite end 883. End 882 has a mounting hole 884 formed therein that allows the locking lever 880 to be rotatably mounted to the gearbox 800. The body 881 has an inner surface 886 with a projecting arc portion 888 that extends inwardly. The body 881 also includes a stepped portion 885 and a varying height outer wall 887.

[0086] Locking lever 880 also includes a locking portion 894 with a locking hole 896 formed therein. The locking hole 896 can receive a fastener or coupler that passes through locking hole 876 as well to connect the free ends of locking levers 860 and 880 together to hold them in place. Locking lever 880 also includes a notch 890 formed therein that receives the tab 872 on coupler 870 from locking lever 860.

[0087] Turning to FIG. 18, locking lever 860 has been rotated about post or fastener 840 which forms an axle, and locking lever 880 has been rotated about post or fastener 842 which forms an axle as well. Locking levers 860 and 880 have been rotated to their locked or closed positions 900. In these positions, the ends 863 and 883 of the locking levers 860 and 880 are proximate to each other, and a fastener can be inserted through locking holes 876 and 896. In addition, the tab 872 on coupler 870 is engaged with the notch 890. When the locking levers 860 and 880 are in these positions, the projecting arc portions 868 and 888 extend through slots in the collar 820 into the cavity 829 (only projecting arc portion 868 is illustrated in FIG. 18). In those positions, the projecting arc portions 868 and 888 can engage the groove 546 of the outer surface 542 of the collar or coupling portion 540 as shown in FIG. 19.

[0088] Turning to FIGS . 20 and 21 , another embodiment of a repositionable gearbox according to the present invention is illustrated. In this embodiment, the gearbox 1000 has a housing 1010 from which a pair of axles or posts 1012 and 1014 extend. The gearbox 1000 has a pair of locking levers pivotally or rotatably coupled to the housing 1010. The housing 1010 also has a collar or wall 1016 that extends outwardly therefrom. The wall 1016 has a pair of opposing slots formed therein.

[0089] Locking lever 1020 has opposite ends 1022 and 1024, with an opening formed in end 1022 for axle 1012, about which locking lever 1020 pivots or rotates. Locking lever 1020 also includes an opening 1026 proximate to end 1024 that can be used to secure locking lever 1020 in a locked position. Locking lever 1020 includes a locking portion 1030 that includes a tab 1036 and a cantilevered latch 1032 with a larger portion or projection 1034 at its distal end. The tab 1036 can be moved to pivot the tab 1036, the latch 1032, and the projection 1034 relative to the rest of the locking lever 1020.

[0090] Locking lever 1040 also has opposite ends 1042 and 1044, with an opening formed in end 1042 for axle 1014, about which locking lever 1040 pivots or rotates. Locking lever 1040 includes an opening 1046 proximate to end 1044 that can be used to secure locking lever 1040 tolocking lever 1020 and in a locked position. Similar to locking lever 1020, locking lever 1040 includes a locking portion 1050 as well. However, locking portion 1050 is different from locking portion 1030. Locking portion 1050 includes a tab portion 1056 and an edge 1052 that has a groove or notch 1054 formed therein.

[0091] In FIG. 20, locking levers 1020 and 1040 are illustrated in their unlocked or opened positions 1060. Turning to FIG. 21, the locking levers 1020 and 1040 are shown in their locked or closed positions 1062. Ends 1024 and 1044 are moved into engagement with each other. This movement results in the projection 1034 of latch 1032 engaging with the notch 1054. In this position, the openings 1026 and 1046 of locking levers 1020 and 1040 are aligned with each other. A coupler or fastener, such as a cable tie, can be inserted into the openings 1026 and 1046 to secure the ends 1024 and 1044 together, thereby maintaining the locking levers 1020 and 1040 in their locked positions 1062. When the locking levers 1020 and 1040 are in their locked positions 1062, the projecting arc portions 1028 and 1048 extend through the slots formed in the wall 1016.

[0092] Referring to FIGS. 22-27, another embodiment of a repositionable gearbox according to the present disclosure is illustrated. Initially referring to FIGS. 22 and 23, the repositionable gearbox 1120 is illustrated as coupled to a feeder mechanism 1100 with a wall or middle wall 1110 located therebetween. Repositionable gearbox 1120 is generally similar to the previously described repositionable gearboxes. In this embodiment, repositionable gearbox 1120 includes a body 1122 that has an inner housing portion 1126 (see FIG. 23) and an outer housing portion 1124, which is shown in FIG. 22 and removed in FIG. 23. The outer housing portion 1124 includes an opening 1128 formed therethrough. The repositionable gearbox 1120 includes several gears, of which gears 1140 and 1150 are visible in FIG. 22 through opening 1128. The repositionable gearbox 1120 include a pair of locking levers 1200 and 1250, which are pivotally mounted and which are shown in their opened or unlocked positions.

[0093] Referring to FIG. 23, gears 1140, 1150, 1160, and 1170 of the repositionable gearbox 1120 are shown. Gear 1140 has teeth 1142 extending around its perimeter, and is mounted on axle 1144. Gear 1150 has teeth 1152 extending around its perimeter, and is mounted on axle 1154. Gear 1160 has teeth 1162 extending around its perimeter, and gear 1170 has teeth 1172 extending around its perimeter. Each of gear 1160 and 1170 is mounted on axle 1174, which enables gears 1160 and 1170 to rotate with each other. The locking levers 1200 and 1250 are positioned on opposite sides of the gearbox and gears 1140, 1150, 1160, and 1170.

[0094] Referring to FIG. 24, some components of repositionable gearbox 1120 are illustrated. A mounting portion 1180 is located between locking arms 1200 and 1250. Mounting portion 1180 includes two circular or cylindrical portions 1181 A and 1181B, with cylindrical portion 118 IB located inside a through opening of cylindrical portion 1181 A. Cylindrical portion 1181 A has an outer surface 1182 with several spaced apart projections 1184 located therealong. Cylindrical portion 1181B has an inner surface 1186 with several spaced apart projections 1188 located therealong.

[0095] In this embodiment, locking lever 1200 has an end 1202 that is pivotally mounted relative to wall 1110 and about which locking lever 1200 can rotate or pivot. Locking lever 1200 has another end 1204 which is opposite end 1202 and which is free to move. Locking lever 1200 is illustrated in its opened or unlocked position 1240 in FIG. 24. Locking lever 1200 can rotate about end 1202 along the direction of arrow “G” to a closed or locked position.

[0096] Similarly, locking lever 1250 has an end 1252 that is pivotally mounted relative to wall 1110 and about which locking lever 1250 can rotate or pivot. Locking lever 1250 has another end 1254 which is opposite end 1252 and which is free to move. Locking lever 1250 is illustrated in its opened or unlocked position 1290 in FIG. 24. Locking lever 1250 can rotate about end 1252 along the direction of arrow “H” to a closed or locked position.

[0097] Turning to FIG. 25, a perspective view of the locking levers 1200 and 1250 is illustrated. End 1202 of locking lever 1200 has a through hole or opening 1206 through which a post or projection can extend to allow locking lever 1200 to rotate about the post or projection. The locking lever 1200 has a body portion 1209 with an inner surface 1210 that has a projecting arc portion 1212. Extending perpendicularly from body portion 1209 is a varying height wall 1214. Located proximate to end 1204 is an engagement tab 1208 that can be contacted by a user to move the locking lever 1200.

[0098] Locking lever 1200 includes a locking portion 1220 located proximate to end 1204. In this embodiment, locking portion 1220 includes a locking component 1222 that has an opening 1224 extending therethrough. Locking portion 1220 also includes a pair of spaced apart walls or guides 1226 and 1230, each of which has an inner surface 1228 and 1232, respectively. Walls 1226 and 1230 define a receptacle 1234 therebetween. Each of the walls 1226 and 1230 has a curved configuration, and the orientation of the walls 1226 and 1230 is such that they are mirror images of each other.

[0099] End 1252 of locking lever 1250 has a through hole or opening 1256 through which a post or projection can extend to allow locking lever 1250 to rotate about the post or projection. The locking lever 1250 has a body portion 1259 with an inner surface 1260 that has a projecting arc portion 1262. Extending perpendicularly from body portion 1259 is a varying height wall 1264. Located proximate to end 1254 is an engagement tab 1258 that can be contacted by a user to move the locking lever 1250. Engagement tab 1258 has several ridges 1255 formed thereon that can be engaged by a user.

[0100] Locking lever 1250 includes a locking portion 1270 located proximate to end 1254. In this embodiment, locking portion 1270 includes a locking component 1272 that has an opening 1274 extending therethrough. The locking component 1272 has an opening 1274 extending therethrough, and an outer surface 1276. When the locking levers 1200 and 1250 are moved to their closed or locked positions, locking portion 1270 engages locking portion 1220. Locking component 1272 is insertable into the receptacle 1234 of locking portion 1220. The outer surface 1276 of locking component 1272 engages the inner surfaces 1228 and 1232 of guides 1226 and 1230, respectively. Guides 1226 and 1230 are curved so that locking component 1272 is retained in receptacle 1234. In addition, when locking component 1272 is positioned in receptacle 1234, through holes or openings 1224 and 1274 are aligned with each other. Accordingly, a securing mechanism, like an elongate member such as a wire or tie, can be inserted through both openings 1224 and 1274 and secured to retain locking levers 1200 and 1250 to each other.

[0101] Referring to FIGS. 26 and 27, a side view and a bottom view, respectively, of locking levers 1200 and 1250 are illustrated. As shown in FIG. 26, ridges 1255 are located on engagement tab 1258 proximate to end 1254 of locking lever 1250, which is opposite to end 1252. The varying height wall 1264 is shown in a profile view. In FIG. 27, locking component 1272 extends from engagement tab 1258 of locking lever 1250 as shown. At one end of the varying height wall 1264, the varying height wall 1264 is the same dimension (such as width or height depending on the orientation) as engagement tab 1258. Similarly, for locking lever 1200, at one end of the varying height wall 1214, the varying height wall 1214 is the same dimension as engagement tab 1208. It can be seen in FIG. 27 how locking component 1272 is aligned with guide 1230, and therefore aligned with receptacle 1234 (not shown in FIG. 27). Locking component 1222 is offset from guide 1230 so that locking component 1222 is adjacent to locking component 1272 when lockingcomponent 1272 is in the receptacle 1234. As a result, through openings 1224 and 1274 are aligned with each other, as described above.

[0102] In one embodiment of the present invention, a middle wall is located between a feeder mechanism and a gearbox and motor combination. The feeder mechanism is mounted to the middle wall and secured thereto using fasteners. The gearbox and motor are mounted on the opposite side of the middle wall and coupled to the feeder mechanism. When the gearbox is coupled to the feeder mechanism, the motor can rotate the rolling members of the feeder mechanism. The gearbox can be coupled to the feeder mechanism and still be adjustable. When the gearbox is not secured or locked in place, it can be rotated by a manufacturer or supplier to a different orientation while still being coupled to the feeder mechanism. After the gearbox and motor are in the desired orientation, the gearbox can be secured in place. The gearbox can be rotated 360 degrees.

[0103] In one implementation, the gearbox is shown with an extending member that has two sets of teeth. The gearbox also has two levers that are pivotally mounted to the body of the gearbox. Each of the pivoting levers includes a projecting arc portion or arcuate portion. An extension of the feeder mechanism is inserted through a hole in the middle wall. The extension includes teeth formed around the perimeter of the extension. The extension also includes a slot that is configured to receive the levers on the gearbox, and in particular, the projecting arc portions of the levers. When the gearbox levers are in their open positions, the gearbox can be axially removed from or mounted on the feeder mechanism. As mentioned above, the gearbox can be rotated 360 degrees, and in one embodiment, select orientations or positions in which the gearbox and motor can be placed can be defined in various degree increments, such as 10-degree increments.

[0104] When the levers on the gearbox body are in their closed positions, the projecting arc portions of the gearbox levers engage slots and the locking geometry on the wire feeder mechanism. This engagement establishes an axial lock between the components. The teeth on the gearbox and on the feeder mechanism engage each other to create a rotational lock.

[0105] In one embodiment, the levers are made of plastic. Each of the levers includes an opening at the end opposite the pivoting end. The ends of the levers can be secured together to maintain the levers in their closed positions by inserting an elongate member, such as a screw, through the lever openings. In an alternative embodiment, a cable strap may be used to secured the ends of the levers together. The mechanism is intended to be a one-time assembly, meaning,the gearbox and motor are rotated to their desired orientation, and then the levers are secured together in their closed positions. If any maintenance is required, or a part needs to be replaced, the cable strap can be cut, and the levers pivoted from their closed positions to their open positions. Another cable strap can be used to subsequently secure the levers together in their closed positions.

[0106] In various embodiments, the mechanism to which the repositionable gearbox is coupled can vary, and does not have to be a wire feeder mechanism. It is to be understood that the repositionable gearbox and motor combination can be used with any mechanical or electromechanical mechanism or device that has a part to be driven by the gearbox and motor combination.

[0107] The repositioning of the gearbox and motor allow them to be universally used. In addition, the gearbox and motor can be retrofit on existing devices and mechanisms, such as existing wire feeders. As a result, the repositionable gearbox and motor can be used with any wire feeder in various locations.

[0108] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “an embodiment” or “one embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0109] While the present disclosure makes reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the sphere and scope of the present disclosure, as defined in the appended claim(s). Accordingly, it is intended that the present disclosure not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof.

Claims

What is claimed is:

1. A repositionable drive system for use with a mechanism, the repositionable drive system comprising: a gearbox containing at least one gear; a motor coupled to the gearbox, the motor being operably connected to the at least one gear to drive the at least one gear; and a locking assembly engageable with the gearbox, wherein the gearbox and the motor are disposable in a first position relative to the mechanism and are disposable in a second position relative to the mechanism, the gearbox and the motor having a different orientation relative to the mechanism when the gearbox and the motor are in the second position relative to when the gearbox and the motor are in the first position, the locking assembly being configured to secure the gearbox and the motor in either of the first position or the second position.

2. The repositionable drive system of claim 1, wherein the motor can drive the at least one gear when the gearbox and the motor are in the first position and when the gearbox and the motor are in the second position.

3. The repositionable drive system of claim 1, wherein the locking assembly has an unlocked configuration in which the gearbox and the motor can rotate about an axis between the first position and the second position, and the locking assembly has a locked configuration in which the gearbox and the motor are prevented from rotating about the axis.

4. The repositionable drive system of claim 1, wherein the mechanism is a wire feeder, and the gearbox and the motor can be disposed in a plurality of positions relative to the wire feeder.

5. The repositionable drive system of claim 1, wherein the locking assembly includes a first locking lever and a second locking lever, and each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position.

6. The repositionable drive system of claim 5, wherein at least one of the first locking lever and the second locking lever is configured to engage a portion of the mechanism to retain the gearbox and the motor in a position relative to the mechanism.

7. The repositionable drive system of claim 5, wherein the first locking lever includes first locking portion and the second locking lever includes a second locking portion, the second locking portion being engageable with the first locking portion to couple the first locking lever to the second locking lever.

8. The repositionable drive system of claim 7, wherein the first locking portion includes a first locking component, the second locking portion includes a second locking component and a pair of walls defining a receptacle therebetween, the receptacle being configured to receive the first locking component, and the first locking component and the second locking component are proximate to each other when the first locking component is in the receptacle.

9. The repositionable drive system of claim 8, wherein the first locking component includes a first hole, the second locking component includes a second hole, and the second hole is aligned with the first hole when the first locking component is in the receptacle.

10. The repositionable drive system of claim 8, wherein the pair of walls includes a first wall and a second wall spaced apart from the first wall, each of the first wall and the second wall has a curved configuration, and the receptacle between the first wall and the second wall has a similar shape to the first locking component.

11. The repositionable drive system of claim 10, wherein the first wall has a first inner surface, the second wall has a second inner surface, and the first locking component has an outer surface, and the outer surface of the first locking component engaging the first inner surface of the first wall and the second inner surface of the second wall when the first locking component is located in the receptacle.

12. A repositionable drive system for use with a wire feeder, the repositionable drive system comprising: a gearbox containing at least one gear; a motor coupled to the gearbox, the motor being operably connected to the at least one gear to drive the at least one gear; and a locking assembly engageable with the gearbox, wherein the gearbox and the motor are disposable in a plurality of different positions relative to the wire feeder, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in a different position, the locking assembly being configured to secure the gearbox and the motor in any one of the plurality of different positions.

13. The repositionable drive system of claim 12, wherein the plurality of different positions includes a first position relative to the wire feeder and a second position relative to the wire feeder, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in the second position relative to when the gearbox and the motor are in the first position.

14. The repositionable drive system of claim 13, wherein the motor can drive the at least one gear when the gearbox and the motor are in the first position and when the gearbox and the motor are in the second position.

15. The repositionable drive system of claim 12, wherein the locking assembly includes a first locking lever and a second locking lever, and each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position.

16. The repositionable drive system of claim 15, wherein the first locking lever includes first locking portion and the second locking lever includes a second locking portion, and the second locking portion is engageable with the first locking portion to couple the first locking lever to the second locking lever.

17. The repositionable drive system of claim 16, wherein the first locking portion includes a first locking component, the second locking portion includes a second locking component and a pair of walls defining a receptacle therebetween, the receptacle being configured to receive the first locking component, and the first locking component and the second locking component are proximate to each other when the first locking component is in the receptacle.

18. A repositionable drive system for use with a wire feeder, the repositionable drive system comprising: a gearbox containing at least one gear; a motor operably connected to the at least one gear to drive the at least one gear; and a locking assembly engageable with the gearbox, the locking assembly including a first pivotally mounted locking lever and a second pivotally mounted locking lever, wherein the gearbox and the motor are disposable in a first position relative to the wire feeder and in a second position relative to the wire feeder, the second position being different from the first position, the gearbox and the motor having a different orientation relative to the wire feeder when the gearbox and the motor are in the first position and in the second position, the locking assembly being configured to secure the gearbox and the motor relative to the wire feeder.

19. The repositionable drive system of claim 18, wherein the motor is configured to drive the at least one gear when the gearbox and the motor are in the first position and also when the gearbox and the motor are in the second position.

20. The repositionable drive system of claim 18, wherein the locking assembly includes a first locking lever and a second locking lever, each of the first locking lever and the second locking lever is pivotable between an unlocked position and a locked position, the first locking lever includes first locking portion and the second locking lever includes a second locking portion, and the second locking portion is engageable with the first locking portion to couple the first locking lever to the second locking lever.

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