Auxiliary Wire Feeder Signal Control via Welding Wire Voltage
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Solution Overview
Problem
Conventional wire feeding systems face challenges in reliably feeding welding wire over long distances due to friction, drag, and synchronization issues between master and slave feeders, leading to inefficiencies and safety concerns like overheating and backlash, especially in robotic applications where wireless communication may be restricted.
Innovation Solution
The system uses the welding wire itself to transmit signals for starting and stopping the rear booster, eliminating the need for cables and synchronization, with a control device responsive to voltage changes to promptly control the booster motor torque, preventing overheating and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a single feeding device pulls the wire from the container over long distances, then the wire can be fed to the welding torch, but the friction and drag increase making reliable feeding difficult
Solution Approach 1:
The wire feeding system is divided into two independent feeding devices: a master feeder positioned near the welding torch and a slave feeder positioned near the wire container. Each device independently feeds wire through separate paths, eliminating the single long-distance feeding problem. The master feeder handles the final feeding to the torch while the slave feeder manages the long-distance transport from the container, with each operating within its optimal feeding range.
2Reliability
If master and slave feeders are synchronized to feed wire together, then wire feeding reliability improves, but system complexity and cost increase
Solution Approach 1:
Both the master feeder and slave feeder are equipped with identical feeding mechanisms and control interfaces. The slave feeder is positioned near the wire container and independently feeds wire through the same type of mechanism as the master feeder near the torch. This duplication of feeding capability eliminates the need for complex synchronization systems, as each feeder operates independently but achieves the same feeding function.
3Adaptability or versatility
If the slave feeder operates independently with delayed response, then manufacturer dependence is reduced, but feeding accuracy decreases due to backlash
Solution Approach 1:
The slave feeder near the wire container is equipped with the same independent feeding mechanism as the master feeder, allowing it to operate autonomously without complex synchronization. Both feeders use identical drive systems and control interfaces, enabling the slave feeder to independently manage wire feeding from the container through the wire guide to the master feeder, eliminating backlash issues while maintaining manufacturer independence.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures reliable and efficient wire feeding over long distances without additional costs or complexity, enhancing the accuracy and lifespan of the booster motor while maintaining safety by directly using the welding wire's voltage signal to control the auxiliary feeder.
Implementation Method 1
uses the welding wire itself to transmit signals for starting and stopping the rear booster, eliminating the need for cables
Implementation Method 2
with a control device responsive to voltage changes to promptly control the booster motor torque
Data Source
AI summary
An auxiliary wire feeder has a pushing device for advancing welding wire, a control device for controlling the pushing device, and an electric contact adapted for being in electrical connection with the welding wire. The electric contact is connected to the control device for supplying a control signal to the control device. A welding system comprises an auxiliary wire feeder of this kind and further a welding torch, a main wire feeder, a wire guide for guiding welding wire from a supply to the welding torch and a welding current contact for supplying welding current to the welding wire. For controlling an auxiliary wire feeder in a welding system having a welding torch, a main wire feeder, a wire guide for guiding welding wire from a supply to the welding torch, a welding current contact for supplying welding current to the welding wire, the control of the auxiliary welding wire feeder is responsive to an electrical signal transmitted via the welding wire.