Ball and socket conduit for welding systems

Abstract

A conduit system includes a tubular member having a plurality of convex portions disposed along a cylindrical portion. A plurality of brackets include concave portions corresponding to the convex portions. The convex portions are retained by the brackets to axially fix the convex portions relative to the brackets. The tubular member is pivotable and bendable relative to the brackets, and rotatable about its longitudinal axis. The tubular member is configured to route one or more cables, lines, and / or wires therethrough and can be used in a welding system. The convex portions may be in the form of a sleeve that is attachable to different locations along the tubular member. The bracket may include a rib that interacts with a corresponding recess in the sleeve to selectively permit or limit pivoting of the sleeve relative to the bracket.

Description

Attorney Docket No. 91694-169BALL AND SOCKET CONDUIT FOR WELDING SYSTEMSBACKGROUND1. Field of the Invention

[0001] The present invention generally relates to welding systems and other robotic systems and more particularly to systems having associated cables and other elongate lines for controlling such systems.2. Description of Related Art

[0002] Metal Inert Gas (MIG) welding also referred to as “wire-feed” or Gas Metal Arc Welding (GMAW) utilizes heat from an electrical arc to melt a consumable electrode to form a weld on a workpiece. A MIG welding system typically includes a power supply, a gas supply, and an electrode supply connected to a welding device or welding gun. A ground cable is used to connect the workpiece to the power supply. The welding device generally includes a handle, a gooseneck, and an end assembly. In a robotic or other welding system, power cables and other wires / tubes may be provided along with a kinematic linkage. Other robotic systems also have cables, wires, tubes, and the like, such as material handling, additive manufacturing, 3D printing, adhesive systems, etc. across many industries also have elongate cables, wires, etc. to manage.

[0003] The welding system can be automatic or semi-automatic and may be manually or robotically controlled. The electrode and gas are coupled through a conduit in the handle and the gooseneck to the end assembly of the welding device. The electrode extends through the contact tip of the end assembly, and the gas moves around the contact tip in the nozzle of the end assembly. When the welding device is activated, the electrode is fed through the contact tip toward the workpiece and the gas is directed through the nozzle towards the workpiece. When the electrode is placed adjacent or in contact with the workpiece, the electrode completes an electrical circuit between the power supply and the workpiece allowing current to flow through theAttorney Docket No. 91694-169 electrode to the workpiece. The current produces an arc between the electrode and the workpiece.

[0004] The heat of the arc melts the electrode and the workpiece in the region surrounding the arc creating a weld puddle. The gas flowing out the nozzle shields the weld puddle from outside contaminants. The type of gas used in MIG welding varies depending on many factors. Noble or inert gases such as Argon are often used. However, Carbon Dioxide (CO2) and a mixture of gases such as CO2and Argon are also used. Once the electrode is moved away from the workpiece, the electric circuit is broken, and the weld puddle cools and solidifies forming a weld.

[0005] In addition to providing the wire electrode and gas through the system to the end assembly, welding systems require the provision of power cables, communication cables, air lines, and the like for controlling and supporting the welding process.

[0006] During the welding process using automatic and semi-automatic welding systems, both manual and robotic, the end assembly may move or be moved to various welding locations relative to the workpiece being welded. Accordingly, the cables or other lines attached to the end assembly, or at other locations of the welding system, may also shift and move. It is desirable to keep such cables and lines secure and protected from the surrounding environment and to limit the exposure and movement of such cables relative to the welding system being articulated during the welding process. Such cables or lines can be bundled and secured together to keep them out of the way, but such bundling and securement can lead to localized stresses on the bundles and attachment mechanisms.

[0007] Accordingly, improvements can be made in the provision of support cables and lines for welding systems.Attorney Docket No. 91694-169SUMMARY

[0008] A conduit system includes a tubular member having a plurality of convex portions disposed along a cylindrical portion. A plurality of brackets include concave portions corresponding to the convex portions. The convex portions are retained by the brackets to axially fix the convex portions relative to the brackets. The tubular member is pivotable and bendable relative to the brackets, and rotatable about its longitudinal axis. The tubular member is configured to route one or more cables, lines, and / or wires therethrough and can be used in a welding system.

[0009] Further objects, features, and advantages of this invention will become readily apparent to persons skilled in the art after a review of the following description, with reference to the drawings and claims that are appended to and form a part of this specification.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 illustrates a gas metal arc welding system;

[0011] Figure 2A illustrates a further detailed view of the gas metal arc welding system within the robotic arm;

[0012] Figure 2B illustrates another further detailed view of the gas metal arc welding system within the robotic arm;

[0013] Figure 2C illustrates another further detailed view of the gas metal arc welding system within the robotic arm;

[0014] Figure 2D illustrates another further detailed view of the gas metal arc welding system within the robotic arm;

[0015] Figure 3 illustrates an exploded view of the gas metal arc welding system;

[0016] Figure 4 is an exploded view of a section of a conduit system for routing cables, wire, and / or lines;

[0017] Figure 5 is a perspective view of the conduit system;Attorney Docket No. 91694-169

[0018] Figure 6 is a cross-sectional view of the conduit system;

[0019] Figure 7 is a top view of the conduit system;

[0020] Figure 8 shows a second embodiment of a conduit system;

[0021] Figure 9 shows the second embodiment with a cable population insert at the end of the conduit;

[0022] Figure 10 shows a bracket of the second embodiment in an open position;

[0023] Figure 11 shows a sleeve of the second embodiment having two halves;

[0024] Figure 12 shows the sleeve within the bracket, with projecting ribs of the bracket disposed within corresponding slots to block pivoting of the sleeve; and

[0025] Figure 13 shows the sleeve within the bracket, with the projecting ribs disposed within recesses, allowing the sleeve to pivot.DETAILED DESCRIPTION

[0026] Referring to Figure 1 , a robotic arm system 10 is shown. It will be appreciated that aspects of the present disclosure may also be used in manual welding systems, which also include the provision of power, gas, etc. via elongate cables or wires.

[0027] The robotic arm system 10 may include a robotic arm assembly 12. Generally, the robotic arm assembly includes a torch end 28 and a drive box 26. A utility cable 24 may be provided so as to feed a wire acting as an electrode into the drive box 26. This wire essentially acts as an electrode for the gas metal arc welding process performed at the workpiece 30. The robotic arm assembly 12 also includes a utility junction box 22 that is configured to receive the wire acting as an electrode from the welding wire spool 18. Wire from the welding wire spool 18 is fed into the utility junction box 22 via an insulated wire conduit 20.

[0028] A digital weld power supply 16 provides power to the robotic arm assembly 12 using one or more connection cables 32. A gas supply 14 provides inert gas to be utilized by the robotic arm assembly 12 when performing a gas metal arc welding operation.Attorney Docket No. 91694-169

[0029] Referring to Figures 2A-2D a detailed view of a drive box system 40 incorporated within the robotic arm assembly 12 is shown. Generally, the system 40 includes a lug 42, a j-arm, and a power block 46. The lug 42 is connected to a first end 43 of the j-arm 44 using a bolt assembly. The j-arm 44 and the lug 42 are generally made of a highly conductive material, such as copper, so as to provide the free flow of electricity to perform the gas metal arc welding operation. The other end of the j-arm 44 has a second end 45. The second end 45 is configured to attach to the power block 46 using a bolt 50. The bolt 50 has a threaded end that threads through an opening located within the second end of the j-arm 44. The power block 46 also has a threaded portion that allows it to mate with the bolt 50 so as to attach the second end 45 of the j-arm 44 to the power block 46.

[0030] In some implementations, one or all of the of lug 42, j-arm 44, the bolt 50, power block 46 and the nozzle 54 may be made of a highly conductive material, for example copper, and may be made of the same material for improved electrical transmission characteristics. In some implementations, a series of the lug 42, j-arm 44, the bolt 50, power block 46 and the nozzle 54 (e.g. the lug 42 and j-arm 44, or the lug 42, j-arm 44, power block 46, and nozzle 54) may be made of a highly conductive material, for example copper, and may be made of the same material for improved electrical transmission characteristics..

[0031] In order to better illustrate the parts of the system 40, an exploded view of the system 40 is shown. As stated before, here, the gas metal arc welding system includes a j-arm 44 having a first end 43 and a second end 45. The first end 43 of the j-arm defines a substantially circular opening 47 within the j-arm 44. The substantially circular opening 47 generally extends through the depth of the j-arm 44. The substantially circular opening 47 is configured so as to mate with the lug 42 (as shown in Figures 2A-2D). This type of mating may occur through the use of a power ball type technology, wherein the lug is shaped slightly spherical so as to mate with a slightly spherical opening 47 of the first end 43 of the j-arm.Attorney Docket No. 91694-169

[0032] The second end 45 of the j-arm 44 also has an opening 51 that extends through the depth of the second end 45 of the j-arm 44. Here, the bolt 50 is configured so as to extend through the opening 51 of the second end 45 of the j-arm 44 and attached to a threaded portion 66 of the power block 46. The bolt 50 has a head 52 that has a diameter such that it clamps the j-arm 44 to the power block 46 when the threaded portion 70 of the bolt 50 is screwed into the threaded portion 66 of the power block 46.

[0033] The bolt 50 generally has a longitudinal diameter and a passageway through the entire length of the longitudinal diameter. The reason for this internal passageway is to allow the flow of an inert gas into the power block 46 as will be described later. The inert gas is provided to the bolt 50 via the use of a coupling 53 having an input 72 for receiving the inert gas from the gas supply. This inert gas travels through the length of the bolt 50 and into the power block 46.

[0034] Referring to the power block 46, the power block 46 generally has a longitudinal axis 60. The longitudinal axis 60 generally defines a first passageway that extends through the length of the power block 46 along the longitudinal axis 60. Running substantially perpendicular to this passageway 64 is a second passageway 65 containing the threaded portion 66. The second passageway 65 runs substantially perpendicular to the axis 60 generally along axis 62. The passageway 65 is in fluid communication with the passageway 64. As such, the passageway 64, 65, and 68 through the bolt 50 are each in fluid communication with each other. As such, inert gas provided to the bolt 50 by the coupling 53 will be essentially provided to the second passageway 65 as well as the first passageway 64. A nozzle end 54 can then be attached to the first passageway 64. Both the wire and the inert gas would be fed through the nozzle 54 and to the torch end 28 shown in Figure 1. One or more O-rings 76 and / or 78 may be utilized so as to attach and create a tight seal between the bolt 50, j-arm 44, and power block 46. Additionally, a larger O-ring 80 may be utilized so as to attach the first end 43 to the lug shown in Figures 2A- 2D.Attorney Docket No. 91694-169

[0035] When thusly assembled, electricity can be provided to the electrode through the j- arm 44 and the power block 46 that the j-arm 44 receives from the lug 42 shown in Figures 2A- 2D. Additionally, the inert gas can then be provided through the j-arm 44 and into the power block 46.

[0036] The power block 46 may also include an eleongated cavity that is configured to receive an end of a power cable. The cavity 82 may take any shape but should be configured so as to have the ability to receive an end of a cable. The cavity 82 may also include threaded portions 83 and 85 for receiving set screws so as to retain any cable inserted within the cavity 82 in direct and electrical contact with the power block 46. The cable that is inserted into the cavity 82 essentially provides electricity to the torch end 28 of the robotic arm assembly 12.

[0037] As discussed above in reference to Figure 1 , one or more connection cables 32 may be provided as part of the system. The system of Figure 1 provides one illustration of various cables or lines, power cables, communication cables, air / gas tubes, etc. Pressurized air, for example, can be used to as a pneumatic drive for some wire feed systems. Inert gas may be provided to the system using gas tubes.

[0038] It will be appreciated that there are variety of welding systems that use a variety of types of cables or lines that may be arranged in different areas relative to the system, and that the particular arrangement of elongate cables or lines of the present disclosure is illustrative of one example.

[0039] Turning now to Figures 4-7, a conduit system 100 is illustrated, which can be used for routing the various cables or lines. The conduit system 100 includes an elongate tubular member 102 that extends longitudinally between a first end 102a and a second end 102b. The tubular member 102 defines a longitudinal central axis A when extending in a straight configuration. The tubular member 102 is hollow with open ends, such that one or more cables or lines may extend through the tubular member 102 from the first end 102a to the second end 102b.Attorney Docket No. 91694-169

[0040] The system 100 is shown in a simplified view having a relatively short length. It will be appreciated that the system 100 may have a length greater than that illustrated in Figures 4-7, and that these figures may be interpreted as illustrating a section of the overall length of the length of the system 100. In one aspect, the system may be produced at a variety of lengths in response to a particular demand, or at an extended length, with the desired length being cut / severed / removed from the overall extended length as necessary.

[0041] The tubular member 102 includes generally cylindrical tube portions 104 along with convex portions 106, which may also be referred to as ball portions or spherical portions. The convex portions 106, as shown, have a partial ball or sphere shape. In one example, the diameter or curvature of the ball portion may be generally constant along the surface of the convex portions 106, like a partial sphere.

[0042] The tube portions 104 may have a corrugated shape, as shown in Figure 4. The convex portions 106 may have a generally smooth and non-corrugated shape. As shown, the inner surface of the tube portions 104 is smooth, but the inner surface of the tube portions 104 may also be corrugated in the same manner as the outer surface, thereby having a generally constant corrugated or wave-like cross-sectional profile. The inner surface of the convex portion 106 may be smooth, similar to the outer surface, or may be corrugated in a manner similar to the outer / inner surface of the tube portions 104. The inner surface of the tubular member 102 may be consistently corrugated or smooth along its length, or it may vary across its length, for instance having a smooth inner surface along the convex portion 106 and a corrugated inner surface along the tube portions 104. It will be appreciated that various cross-sectional shapes of the tubular portion 104 and the convex portions, including different thicknesses in different regions, may be used, without departing from the spirit and scope of the disclosure.

[0043] The system 100 is configured to be used with cables C or lines that are not generally being moved through the system after installation. Accordingly, the inner surface does not necessarily need to be tailored for a particularly frictional or resistance value. Put anotherAttorney Docket No. 91694-169 way, the inner surface must allow the cables or lines to be pushed or pulled through the conduit to some extent, and also to be removed, but during normal use once installed, the cables or lines are not intended to be fed through the system 100. However, it will be appreciated that the conduit provided by the system 100 may still be used for the feeding of elongate cables or wires during use, such as to provide a cable, tubing, or wire from a spool or the like in a number of industrial or commercial settings.

[0044] In one aspect, the tube portions 104 and convex portions 106 may be coextruded. Put another way, these portions may be integrally formed of the same material and provided as a single solid piece, rather than as separately assembled pieces. Accordingly, separate fixing elements, such as mechanical fasteners or adhesives or the like need not be provided to secure the convex portions 106 to the tube portions 104 to form the overall tubular member 102. Rather, the convex portions 106 may be formed during the extrusion process of the overall tube at various intervals during the extrusion process. However, in another aspect, the convex portions 106 may be separate pieces, such as sleeves or rings or the like, and may be provided over the outer surface of the tubular portion 104 and fixed in place via an adhesive or other fixing mechanism. In another aspect, individual tubular portions 104 may be attached to individual convex portions 106. However, the preferred form is the coextruded form.

[0045] In one aspect, the convex portions 106 are evenly spaced along the length of the tubular member 102. Accordingly, the tube portions 104 likewise have similar lengths disposed between each of the convex portions 106. However, if desired, the convex portions 106 may be spaced apart at different intervals depending on the needs of the user. However, for ease of manufacturing and to enhance the flexibility of the system 100 to be installed in a variety of operational environments, a given and known spacing between the convex portions 106 may be preferable.

[0046] Thus, the system may be provided in various forms. For instance, the tubular member 102 may include convex portions 106 as a consistent fixed spacing along its length, suchAttorney Docket No. 91694-169 that the tubular member 102 may be more universally used for a system where specific spacing of connection points is not known in advance. In this approach, it is expected that multiple ones of the convex portions 106 may be unused. It may further be expected that different quantities of unused convex portions 106 may be provided between instances of convex portions 106 that are in use.

[0047] For a more specific application, the tubular member 102 may be provided with a specific spacing of the convex portion 106 that may not be consistent along its length. Rather, the convex portions 106 may be provided only the areas where the fixed position is expected. In this aspect, the tubular member 102 can be specifically tailored to the desired use case, and the material used for the convex portions may be saved.

[0048] The in-use convex portions 106 function as anchor points for the tubular member 102 for installation relative to the welding system 10 (or other industrial system). To anchor the tubular member 102, the system 100 includes a plurality of brackets 108, which may be disposed at a variety of locations along the desired path for the conduit.

[0049] The figures illustrate a single bracket 108 disposed on a middle one of the three illustrated convex portions 106. It will be appreciated that additional brackets 108 are envisioned at additional locations along the length of a tubular member longer than that illustrated. The brackets 108 may be disposed at multiple locations, but need not be disposed at each of the convex portions 106. Accordingly, it is likely that only some of the convex portions 106 will be anchored at brackets 108, with other convex portions 106 being non-anchored and free from attachment to said brackets 108.

[0050] The brackets 108 may be placed along the desired conduit path at variable spacing to accommodate different installation environments. Accordingly, the number of non-anchored convex portions between the brackets 108 may vary depending on the spacing of the brackets 108 relative to each other.Attorney Docket No. 91694-169

[0051] The brackets 108 may be oriented relative to each other at different orientations. For example, the brackets 108 do not need to be aligned with each other. Rather, the brackets 108 may be oriented at angles relative to each other about multiple axes, thereby allowing the tubular member 102 to bend and curve around various obstacles or other structural impediments adjacent the weld system 10 or other system. The brackets 108 may be placed at nearly any orientation due to the cooperation between the convex portion 106 shape of the tubular member 102 and that of the bracket 108, the repeated spacing of the convex shapes 106, and the mechanical flexibility of the tubular member 102 provided in the tube portion 104.

[0052] With further reference to the cooperating shapes of the convex portion 106 and the brackets 108, the brackets 108 define a recess or cavity or concave portion 110 having the same general curvature as the convex portions 106. The concave portion 110 may be provided by a pair of cooperating halves of the bracket 108. Put another way, the bracket 108 may include a first portion 108a and a second portion 108b. The portions 108a and 108b may each define generally half of the concave portion 110.

[0053] The portions 108a and 108b may be connected to each other via cooperating structure, for instance via the use of protrusions 112 formed on the first portion 108a that are received between pairs of lugs 114 formed on the second portion 108b. The protrusions 112 and lugs 114, when mated with each other, may define a through-bore 116. Pins 118 may be disposed through the bore 116 to link the portions 108a and 108b together. The two portions 108a and 108b may alternatively connect to each other via a detachable snap fit connection, or a one-way connection similar to a zip tie of the like, thereby limiting tampering or simple removal of the conduit from the bracket 108. The bracket 108 may be symmetrical, such that one pin may be removed at either side, allowing the portions to pivot relative to each from either side. It will be appreciated that other hinge structures or connection mechanisms between the two portions, and while such connections may not provide all of the same advantages as those illustrated, the present disclosure is not limited to the hinge structure or connection arrangement illustrated. ForAttorney Docket No. 91694-169 instance, while the pins 118 are illustrated, such pins are optional, and other securement mechanisms may be used.

[0054] The convex portion 106 of the tubular member is disposed within the concave portion 110 to secure the tubular member in its longitudinal direction. Put another way, when disposed within the bracket 108, the convex portion 106 cannot be pulled out in either direction. The tubular conduit is therefore not simply held in place by a frictional connection that requires hold-down members in multiple locations to provide a sufficient longitudinal retention.

[0055] The cooperating curvatures of the convex portion 106 and concave portions 108 allows the tubular member 102 to pivot relative to the bracket 108 and its anchored location. Thus, the tubular member can bend and flex relative to the bracket 108 via this pivoting ability, thereby reducing localized stresses that may arise due to bending of the tubular member. For instance, in a friction based hold-down member, the cable or other member being held down can end up being damaged or bent due to an attempt to turn or redirect the cable relative to its anchored location. The convex portion 106 allows the conduit to pivot relative to the bracket 108, while also protecting the contents from being bent beyond the curvature of the tubular member 102 itself. It can be seen from the figures that the tubular member 102 will be limited in the amount of possible pivoting relative to the bracket 108 based on the relative sizing of the tubular member, convex portion, and concave portion. The larger the convex portion 106 is relative to the concave portion 110, the more pivoting is permitting. However, because the tubular member 102 extends from both sides of the convex portion 106, the actual overall curvature of the bend of the tubular member 102 remains limited by the ability of the tubular member to compress on lateral side and expand on the opposite lateral side from the corrugations. Thus, the overall possible curvature through the brackets 108 can be adjusted via the corrugations or other bending properties of the tubular member 102.

[0056] Additionally, due to the cooperating curved surfaces, which are preferably smooth, the tubular member 102 may also rotate about its longitudinal axis. Thus, the tubular memberAttorney Docket No. 91694-169 can twist relative to the brackets 108, again with reduced stresses, such as torsional stresses, that may arise from the desired bent path.

[0057] The anchoring of the tubular member 102 at each bracket location may be provided without providing a substantial clamping force or the like between the bracket 108 and the convex portion 106 or tubular member 102. Accordingly, the tubular member 102 can be made of a thinner and more flexible material that does not necessarily need to withstand substantial clamping or fixing forces to keep the conduit in place and in its desired shaped path. The lack of clamping force likewise allows the tubular member 102 to bend and flex slightly during use and installation.

[0058] The two portions of the bracket 108 may be constructed in different external shapes, while still having the cooperative concave curvature to match the convex portions 106. For instance, the first portion 108a could have a larger or smaller profile relative to the second portion 108b. The two portions 108a and 108b could be hinged together at one side, in another aspect, via a mechanical hinge, or via a living hinge (thin strip of molded material that allows the two portions to move relative to each other to open and close, while retaining the two portions to each other when in the open position, with the portions of the bracket being part of the single bendable structure). A different securement mechanism between the portions could be used. In any case, by surrounding the convex portion 106 with the two portions that define the concave portion 110, the tubular member 102 may be secured at any of its convex portions 106, thereby being secured in the axial direction, but pivotable and rotatable relative to the location of the anchoring provided by the bracket 108.

[0059] Thus, a complicated curvature for the desired guide path of the cable or lines to be routed through the conduit can be provided. The conduit system 100 provides protection to the cabling and a consistent and known location, thereby improving reliability and workplace safety. The conduit system 100 has been described as being used in a welding system (in which various power and communication cables may be present), but can also be used in other wire bundlingAttorney Docket No. 91694-169 environments, such as vehicle wire harness, electrical cable routing, flexible water pipe routing, or the like.

[0060] Various suitable materials, dimensions, and diameters may be used to accommodate the needs of the overall system.

[0061] In a further aspect of the disclosure, another embodiment of a system 200, similar to system 100, is provided, as shown in Figures 8-13.

[0062] In general, as shown in Figures 8-10, the system 200 includes alternative arrangements of a bracket 208, tubular member 202, and convex member 206. In view of the similarities between the systems 100 and 200, it will be appreciated by those skilled in the art that various features associated with system 100 as illustrated and system 200 as illustrated may be applicable to each other, such that features of system 100 may be applied to system 200, and features of system 200 may be applied to system 100, depending on the specific needs of the end user.

[0063] System 200 includes bracket 208, shown in Figure 10, including a top portion 208a and a bottom portion 208b. The top and bottom portions 208a, 208b are connected via a hinge 212 at one lateral side, such that the bracket 208 may be selectively opened and closed. The bracket 208 includes an inner concave surface 210. The two portions of the bracket 208 may include cooperating features for aligning and securing the two portions together when closed. For instance, a flexible latch 214a may be disposed on the bottom portion, with a cooperating ledges 214b disposed on the top portion to secure the bracket in the closed position. A ridge 215b may project downwardly from the top portion near the ledge 214b, and be received in a corresponding groove 215a formed in the bottom portion. The ridge and groove provide an alignment even when the latch is flexed outward and disengaged from the ledge, and also allow the latch to be more narrow than the opening around the ledge, in order to receive the latch during a closing operation. The ridge may have tapered sides to help guide the ridge into the groove during closing.Attorney Docket No. 91694-169

[0064] The top and bottom portions 208a, 208b may each include a projecting rib 211 extending from the concave surface 210. As further described below, the rib 211 is provided to cooperate with the structure of the convex member 206, to selectively allow the convex member 206 to pivot relative to the bracket or to prevent / limit pivoting. The rib 211 is configured to be received in a particular recessed portion of the convex member, as further described below.

[0065] As shown in Figure 11 , the convex portion 206 may be in the form of two sleeve portions 206a. In one aspect, the portions 206a are symmetrical halves, such that the two portions can be assembled without requiring a specific top portion and bottom portion. Thus, only one of the portions 206a will be described. The sleeve portions 206a are configured to be assembled to define an overall convex portion 206 or sleeve 206. Reference to the sleeve 206 and the convex portion 206 may be used interchangeably herein.

[0066] The sleeve portion 206a includes an enlarged recess 207 formed in the convex outer surface thereof. The recess 207 is sized and shown as a rectangle / square area, but other shapes of the recess 207 may also be used. The recess is “enlarged” relative to the rib 211 that projects from the concave surface 210 of the bracket. Such that the rib 211 will fit within the recess 207. The width / size of the recess 207 determined the amount that the sleeves 206 can pivot relative to the bracket 207. The amount of pivoting is limited by the walls of the recess impacting the rib 211 during a pivoting movement.

[0067] On another area of the convex surface of the sleeve portion 206a, the sleeve portion 206a includes a slot 209 that extends in a circumferential direction around the sleeve portion 206a. The slot 209 has a size / width generally corresponding to the rib 211. The slot 209 is configured to receive the rib 211 in another installation arrangement of the sleeve 206, in order to fix the sleeve 206 in place relative to the bracket 208, thereby limiting or preventing pivotal movement of the sleeve 206.

[0068] When the two portions 206a area assembled together, there are two recesses 207 and two slots 209 on opposite sides of the sleeve 206, such that the sleeve 206 may be receivedAttorney Docket No. 91694-169 in the bracket 208 with the rib 211 on each upper / lower portion of the bracket being received in either the recesses or the slots.

[0069] Figure 13 shows the ribs 211 disposed within recesses 207, allowing the sleeve 206 to pivot. Figure 12 shows the ribs 211 disposed within slots 209, holding the sleeve 206 in place and blocking pivotal movement.

[0070] It will be appreciated that other recessed shapes may be provided alternatively or additionally, to provide additional options for the amount of allowed pivoting, or to alter the amount of pivoting that is permitted, and that the sleeve 206 is not limited only to the two shapes shown and described.

[0071] As shown in Figure 11 , the sleeve 206 also includes plurality of circumferential ridges 213 on an internal surface of the sleeve 206. The ridges 213 are sized and arranged to cooperate with an external corrugated ridge structure of the flexible tube 204. Thus, the sleeve 206 may be assembled to any point along the tube 204 to provide a connection point of the tube 204 to the associated mounting structure of the robotic system (such as a robotic welder with fixed and moveable portions).

[0072] The sleeve portion 206a may include alignment pins and mounting holes arranged in a rotationally symmetrical manner, such that the pin on one side is received in a hole on the other side, with a further hole permitting the introduction of a fastener or the like to secure the two portions 206a together onto the flexible tube 204.

[0073] As shown in Figure 8, in addition to being located on the flexible tube 204 to be received within the bracket 208 mounted at a desired location, the sleeves 206 may also be provided on the flexible tube 204 in areas where impact may occur between the tube 204 and the system. For instance, a particular area of the flexible tube 204 may not be designed to be provided in a bracket, and may allow for axial movement of the tube 204 as the robotic system operates, but the tube 204 being free at this area may cause the tube to interact with or contact other adjacent structure. The sleeve 206 can accordingly be provided at such an area forAttorney Docket No. 91694-169 protection and as a bumper to protect the tube 204. The sleeve 206 can be selectively replaced in the event the sleeve 206 becomes worn, without replacing the entire tube 204.

[0074] Thus, the convex member 206 in the form of the sleeve 206 that can be provided at a specific location to interact with various bracket locations or locations where a bumper is needed allow for a robust and modular design that can be specifically tailored for the desired end used. Moreover, the system 200 may be modified by the end user in the vent of design changes or use on a different system.

[0075] Of course, it will be appreciated that the recesses on the convex member 206 and the rib 211 can be used with the bracket 108, or the integral coextruded tube 104 having the convex portions 106 can be molded / formed to have recesses and operate with the bracket 208. These are just some examples of the features of system 100 and 200 being interchangeable.

[0076] In yet another aspect, shown in Figures 8 and 9, a cable population insert 230 may be provided within the sleeve 206. The cable population insert may include a specific arrangement of holes or the like to hold specific types of the cables for the operation of the associated robotic or kinematic system. These arrangements are sometimes known as cable stars. As shown in Figure 9, the cable population insert 230 may have a corrugated outer surface, such that the internal ridges of the sleeve 206 may secure the insert 230 into the sleeve, such as at a location at the end of a conduit where the cables enter. The sleeve 206 can also be used to connect abutting ends of the two flexible tubes 204. The flexible tube 204 may also include an outer jacket that extends around the flexible tube in areas where the sleeves 206 are not installed.

[0077] As a person skilled in the art will readily appreciate, the above description is meant as an illustration of an implementation of the principles of this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation, and change, without departing from the spirit of this invention, as defined in the following claims.

Claims

Attorney Docket No. 91694-169CLAIMS1. A conduit system comprising: a tubular member extending from a first end to the second end and configured to route one or more cables, wires, and / or lines therethrough; a cylindrical tube portion of the tubular member; a plurality of convex portions projecting outwardly from the cylindrical tube portion; a bracket having a concave inner surface corresponding to the convex portions; wherein the concave surface of the bracket receives one of the convex portions and axially fixes the convex portion of the tubular member relative to the bracket.

2. The system of claim 1 , wherein the convex portions and the cylindrical tube portion are coextruded and integrally formed as a single piece.

3. The system of claim 1 , wherein the tubular member is flexible.

4. The system of claim 1 , wherein the cylindrical tube portion is corrugated.

5. The system of claim 1 , wherein the convex portions are equally spaced along the cylindrical tube portion.

6. The system of claim 1 , wherein the convex portions are non-equally spaced along the cylindrical tube portion.

7. The system of claim 1 , wherein the convex portion is separately formed relative to the cylindrical tube and fixed thereto.Attorney Docket No. 91694-1698. The system of claim 1, wherein the bracket includes a first portion and a second portion, where the first portion and second portion combine to define the concave surface.

9. The system of claim 8, wherein the first portion includes a pair of projections that are received between lugs of the second portion.

10. The system of claim 9, wherein the first and second portions are held together via at least one pin extending through the projection and the lugs.

11. The system of claim 8, wherein the first portion is pivotable relative to the second portion to open and close the bracket to receive one of the cylindrical portions.

12. The system of claim 9, wherein the first portion is symmetrical and the second portion is symmetrical, such that the first portion and the second portion can be pivoted relative to each other at either side.

13. The system of claim 1 , wherein the tubular member is rotatable about a longitudinal axis thereof.

14. The system of claim 1 , wherein the tubular member is pivotable relative to the bracket.

15. The system of claim 1 , wherein the convex portion is axially longer than the concave portion, such that a portion of the convex portion is exposed relative to the bracket.Attorney Docket No. 91694-16916. A conduit system comprising: a tubular member extending from a first end to the second end and configured to route one or more cables, wires, and / or lines therethrough; a cylindrical tube portion of the tubular member; a convex sleeve attached to and projecting outwardly from the cylindrical tube portion; wherein the sleeve includes two portions that are detachable from each other such that the sleeve is attachable to various locations along the length of the tubular member.

17. The system of claim 16, further comprising: a bracket having a concave inner surface corresponding to the convex sleeve; wherein the concave surface of the bracket receives sleeve and axially fixes the convex portion of the tubular member relative to the bracket.

18. The system of claim 17, wherein the bracket includes at least one rib projecting out form the concave surface, and wherein the sleeve includes a recess in an outer convex surface of the sleeve wherein the recesses receives the rib when the sleeve is received within the bracket.

19. The system of claim 18, wherein the sleeve includes multiple recesses, wherein one recess is in the form of a slot having a size corresponding to the rib and another recess is in the form of an enlarged recess having a size larger than the rib, such that when the rib is received in the slot the sleeve is blocked from pivoting relative to the bracket, and when the rib is recessed in the enlarged recess, the sleeve is permitted to pivot relative to the bracket.

20. The system of claim 16, further comprising a cable population accessory received within a portion of the sleeve, wherein the sleeve is attached at a terminal end of the cylindrical tube portion.

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