Dual Wire Feed Roll Geometry for Wider Weld Beads at Lower Energy
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Solution Overview
Problem
Existing welding technologies face challenges in increasing the width or length of the weld bead without simultaneously increasing the heat input and weld bead profile, which can be undesirable for certain mechanical applications.
Innovation Solution
A dual wire configuration using two drive rolls with annular or circumferential grooves to feed two welding wires simultaneously, where a biasing member ensures contact between the wires, allowing for independent control of wire diameters and orientations to achieve the desired weld profile without increasing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a larger electrode diameter is used to increase weld bead width and length, then the weld puddle is elongated and widened, but more energy is needed and heat input increases
Solution Approach 1:
The invention divides the single electrode function into two separate electrodes. Instead of using one large electrode, two smaller electrodes are used simultaneously, each contributing to the weld bead formation. This segmentation allows the weld bead width to be increased through the combined effect of two electrodes while maintaining smaller individual electrode diameters, thereby reducing the energy requirement compared to a single large electrode.
2Area of stationary object
If a larger electrode diameter is used to increase weld bead width, then the weld puddle is elongated and widened, but the weld bead profile may not be ideal for certain mechanical applications
Solution Approach 1:
The invention applies local quality by allowing different electrodes to have different diameters, materials, or configurations tailored to specific requirements. Each electrode can be optimized for its local function, and their combined effect produces a weld bead with the desired width and profile characteristics that would be difficult to achieve with a single electrode of uniform properties.
3Use of energy by moving object
If two smaller electrodes are used simultaneously to avoid increasing energy consumption, then weld bead width can be increased, but a mechanism is needed to ensure proper contact and feeding of both wires
Solution Approach 1:
The invention merges the feeding and contact functions of two separate electrodes into a unified system. The drive rolls are configured with grooves that accommodate both electrodes, and the electrodes are positioned to contact each other, creating a combined feeding path. This merging simplifies the overall system compared to having completely independent feeding mechanisms for each electrode.
Data Source
AI summary
A welding or additive manufacturing wire drive system includes a first drive roll having a first annular groove, a second drive roll having a second annular groove, a first welding wire located between the drive rolls in the annular grooves, and a second welding wire located between the drive rolls in the annular grooves. A biasing member biases the first drive roll toward the second drive roll to force the first welding wire to contact the second welding wire. The first welding wire contacts each of a first sidewall portion of the first annular groove, a first sidewall portion of the second annular groove, and the second welding wire. The second welding wire contacts each of a second sidewall portion of the first annular groove, a second sidewall portion of the second annular groove, and the first welding wire. The drive rolls rotate in opposite directions thereby moving the welding wires through the wire drive system.