Modular Wire Guide System for Welding Friction Reduction
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Solution Overview
Problem
Wire dispensing systems face challenges with increased friction and wear due to bends and turns in the wire path, leading to higher pulling forces and conduit wear, and require flexible and easily modifiable solutions to accommodate varying weld stations.
Innovation Solution
A modular wire guide system comprising interconnected modules with mirrored halves, allowing for flexible assembly and reduced friction through curved surfaces and bearing cavities, enabling the wire to pivot and rotate while maintaining connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed conduit is used for wire delivery, then the wire path is stable and predictable, but the system cannot adapt to varying weld station locations and requires time-consuming modifications
Solution Approach 1:
The wire guide system is divided into multiple modular segments that can be independently connected and reconfigured. Each module contains wire guide features and can be assembled in different configurations to accommodate varying weld station locations without modifying the entire conduit system.
Solution Approach 2:
The wire guide system transitions from a fixed, static conduit to a dynamic, reconfigurable modular assembly. The modules can be easily connected and disconnected to adapt to different weld station positions, providing flexibility while maintaining system integrity.
2Length of moving object
If the wire makes multiple bends and turns to reach the weld gun, then the wire can reach distant or angled locations, but friction accumulates increasing the pulling force required
Solution Approach 1:
The wire guide modules incorporate curved surfaces and rounded wire paths instead of sharp angles. This reduces friction and wear on the wire during bending, allowing the wire to travel longer distances with less accumulated friction and lower pulling forces required.
3Ease of operation
If the wire travels through a non-linear route with multiple bends, then the wire can reach the weld gun from a stationary spool, but wear and tear increases on both the wire and conduit
Solution Approach 1:
Rounded wire guide surfaces and curved paths within the modules reduce stress concentrations and friction during wire bending, thereby reducing wear and tear on both the wire and the guide components, improving overall system reliability.
Solution Approach 2:
The modular wire guide system uses flexible, wear-resistant materials and smooth internal surfaces that accommodate wire bending while minimizing friction and wear, extending the service life of both the wire and guide components.
Data Source
AI summary
A flexible wire guide conduit includes a plurality of modules that can be chained together and can pivot and rotate relative to each other. Each module is formed of two halves that are generally mirrors of each other across a mating plane between the halves. Each module includes an upper flange and a lower flange defining a receiving cavity. Each module includes a tongue member sized to correspond to the cavity that is received in the receiving cavity. The flanges include protrusions extending into the cavity to define a pivotable axis. The tongue includes a bore that receives the protrusions of the adjacent module in the chain. The flanges each include a peg extending into the cavity. The pegs are received in slots formed in the tongue and will slide within the slots during pivoting. The pegs and slots define the degree of pivoting permitted between adjacent modules.