Spool Gun Adapter Voltage Conversion for Wire Feeding
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Solution Overview
Problem
Many existing welders are not adaptable to use with spool guns, making it expensive and complicated to operate spool guns with these welders, especially when they are low-cost, and this is exacerbated by issues such as soft filler metal welding wire binding and feeding problems.
Innovation Solution
A welding gun adapter that includes a welder interface and a welding gun interface, with a circuit board that receives input voltage from the welder and outputs a different voltage to the spool gun, powering the motor through pulse width modulation, allowing the spool gun to be used with non-'spool gun ready' welders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spool gun is used with soft filler metal welding wire, then wire binding and feeding problems are reduced, but the system complexity and cost increase due to requiring a spool gun with motor
Solution Approach 1:
The patent introduces an adapter as an intermediary device that connects a standard welding gun to a spool gun wire feed system. The adapter includes a motor housing containing a wire drive motor and gear assembly, which mediates between the welder's wire feed mechanism and the spool gun's wire spool, enabling soft wire feeding without requiring the spool gun to be permanently modified or integrated into the welder
2Reliability
If a spool gun is integrated into the welder, then wire feeding is improved, but the welder cost and complexity increase significantly
Solution Approach 1:
The patent segments the spool gun system into a separate, portable adapter unit that can be attached to or removed from the welding gun independently of the welder. This segmentation allows the wire feeding mechanism to be provided on-demand without permanently modifying the welder, reducing manufacturing costs and maintaining compatibility with existing welders
3Adaptability or versatility
If a spool gun adapter is added to a welder, then spool gun compatibility is achieved, but the device complexity and cost increase
Solution Approach 1:
The adapter is designed with universal compatibility features, including a standardized motor housing that can accommodate different wire drive motors and a flexible mounting system that can be attached to various welding gun configurations. The adapter serves multiple functions: providing motor power, driving the wire spool, and interfacing with different gun types, making it a versatile solution for achieving spool gun compatibility across multiple welder models
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
Enables the use of spool guns with welders that are not originally compatible, providing a cost-effective solution by using the welder's output power to control and power the spool gun, reducing the risk of wire binding and improving welding efficiency.
Implementation Method 1
a circuit board configured to receive an input voltage from the welder to which the welder interface is coupled and output an output voltage to the welding gun to which the welding gun interface is coupled, wherein the output voltage is different than the input voltage
Implementation Method 2
driving a motor of a welding gun with the received voltage, wherein the motor is voltage-controlled through pulse width modulation by the control board
Data Source
AI summary
The present disclosure provides a welding system having a welder, a welding gun, and a welding gun adapter, the welding gun being a spool gun with an attached motor. The welding gun adapter receives welding power from the welder, and converts it to output power suitable for driving the motor of the welding gun. The welding gun adapter also uses received welding power from the welder for control power. The present techniques allow for the use of welding guns requiring motor power to be used with any ordinary welder.