Dual-Wire Drive Roll Groove for Wider Weld Beads
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Solution Overview
Problem
Existing welding techniques face challenges in increasing the width or length of the weld bead without increasing the electrode diameter, which results in higher energy consumption and non-ideal weld profiles.
Innovation Solution
A dual wire configuration system using two spindles and drive rolls with circumferential grooves to simultaneously feed two welding wires of different diameters or compositions, allowing for controlled contact and offset positioning to achieve the desired weld profile without the need for larger electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the diameter of the electrode is increased to increase the width or length of the weld bead, then the weld bead width and length are improved, but the energy consumption increases
Solution Approach 1:
The invention divides the single electrode system into two separate electrodes. Instead of using one large-diameter electrode, the system employs two smaller-diameter electrodes that can be fed simultaneously through the wire drive system. This segmentation allows the welder to achieve increased weld bead width and length through the combined effect of two electrodes, while each electrode continues to operate at its optimal, smaller diameter, thus avoiding the excessive energy consumption associated with a single large electrode.
2Length of moving object
If the diameter of the electrode is increased to elongate the weld puddle, then the weld puddle length is improved, but the heat input increases
Solution Approach 1:
The invention segments the welding function into two separate electrodes, allowing each to contribute to elongating the weld puddle. By using two smaller electrodes instead of one large electrode, the system achieves extended weld puddle length through the combined arc action, while maintaining lower heat input per electrode. This segmentation enables precise control over puddle geometry without the thermal penalty of a single high-power electrode.
3Productivity
If the diameter of the electrode is increased to increase the wire deposition rate, then the deposition rate is improved, but the weld bead profile becomes non-ideal
Solution Approach 1:
The invention divides the deposition function between two electrodes, allowing each electrode to operate at an optimal smaller diameter that produces an ideal weld bead profile. The combined deposition from both electrodes achieves high overall wire deposition rate, while each individual electrode maintains the geometric conditions necessary for forming a sound, well-shaped weld bead. This segmentation resolves the conflict between deposition rate and bead profile quality.
4Use of energy by moving object
If two smaller electrodes are used simultaneously to avoid increased energy consumption, then the energy efficiency is improved, but the device complexity increases
Solution Approach 1:
The invention merges two separate wire feeding systems into a single integrated drive mechanism. The wire drive system incorporates two drive rolls with circumferential grooves that can simultaneously grip and feed two different wires through a unified control system. This merging approach maintains energy efficiency by using two smaller electrodes while minimizing the increase in device complexity through integrated design. The system combines spindles, drive rolls with grooves, and control mechanisms into a cohesive unit that feeds two wires simultaneously.
Data Source
AI summary
A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.