Welding Wire Drive Roll Crater Finishing for Burr-Free Feeding

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Solution Overview

Problem

Existing drive rolls for welding wire electrodes face issues with surface finishing, as knurling leads to burr formation and requires specialized tooling, while lacking sufficient friction for cored or soft wires, causing deformation and feeding problems.

Innovation Solution

The use of laser-formed craters on the sidewalls and groove bases of drive roll grooves provides a surface finishing that enhances friction without deforming the wire, reducing burr formation and tooling requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If knurled surface finishing is used on drive roll grooves, then friction is increased to enable driving cored or soft wires at lower clamping pressure, but burrs are raised on the wire surface which wear out the torch liner

Engineering Contradiction:

ImprovefrictionVSAvoidburr formation

Core Design Contradiction:

ForceVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical knurling process with a laser-based surface treatment process. The laser forms craters on the drive roll groove surfaces without the mechanical contact that causes burr formation. This substitution maintains the friction enhancement benefit while eliminating the harmful burr generation on the wire surface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the surface topology parameter by creating craters with specific depth ranges (0.001-0.006 inches) and spacing patterns. These controlled parameter changes provide the necessary friction increase while the precise control over crater formation prevents the uncontrolled material deformation that leads to burrs.

Inventive Principle:

Principle #35Parameter changes

2Force

If knurling is used to provide friction for driving cored or soft wires, then specialized tooling is required, but this increases device complexity and manufacturing cost

Engineering Contradiction:

ImprovefrictionVSAvoidtooling requirements

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical knurling tooling system with a laser-based system. The laser can be programmed to create the desired crater patterns without requiring specialized mechanical tooling, thereby reducing device complexity and tooling costs while maintaining the friction enhancement function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser system can be integrated directly into the drive roll manufacturing process, allowing the drive roll to be self-finished without separate tooling operations. The laser forms the craters directly on the groove surfaces during or after groove formation, eliminating the need for additional specialized tooling steps.

Inventive Principle:

Principle #25Self-service

3Reliability

If high clamping pressure is applied to drive solid welding wires, then feeding reliability is improved, but cored or soft wires are deformed or crushed

Engineering Contradiction:

Improvefeeding reliabilityVSAvoidwire integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the surface friction parameter by creating craters on the drive roll grooves. This increases the coefficient of friction between the drive roll and wire, allowing the same feeding force to be achieved at lower clamping pressures. The crater geometry (depth, spacing, distribution) is optimized to provide sufficient friction for reliable feeding without excessive pressure that would deform or crush the wire.

Inventive Principle:

Principle #35Parameter changes

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

The laser-formed craters improve wire feeding by providing suitable friction at lower clamping pressures, minimizing burr formation and tool wear, and enabling efficient operation with cored or soft wires.

Implementation Method 1

The first sidewall surface includes a first surface finishing comprising a first ring of laser-formed craters along the first sidewall surface

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

laser-formed craters

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS12583058B2Surface modification of welding wire drive rolls

Publication Date: 2026.03.24 LINCOLN GLOBAL INC

AI summary

A welding wire drive roll has an outer circumferential surface having a circumferential groove projecting radially inward from the outer circumferential surface. The circumferential groove is formed by a first sidewall having a first sidewall surface, a second sidewall having a second sidewall surface, and a groove base extending between the first sidewall and the second sidewall. The first sidewall surface includes a first surface finishing comprising a first ring of laser-formed craters along the first sidewall surface. The second sidewall surface includes a second surface finishing comprising a second ring of laser-formed craters along the second sidewall surface.