Spool Gun Wire Dispensing with De-Reeling Arm for Less Downtime
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Solution Overview
Problem
Conventional spool gun welding systems are limited to small wire spools, requiring frequent replacements and increasing downtime due to the need for constant wire spool changes, which is labor-intensive and inefficient.
Innovation Solution
A system that allows conversion from a small wire spool to a larger spool (e.g., 16 pounds) using a de-reeling arm, conduit, and roller to channel the welding wire, supported by a shaft and brake, enabling continuous welding with reduced downtime and lighter spool gun weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a small wire spool is used in a spool gun, then the spool gun remains portable and easy to handle, but frequent wire spool replacements are required, increasing downtime and labor
Solution Approach 1:
The system divides the wire supply into two segments: a large stationary wire spool and a portable spool gun. The de-reeling arm acts as an intermediary that transfers wire from the large spool to the gun, allowing the gun to remain lightweight and portable while the bulk wire storage remains fixed. This segmentation resolves the contradiction by separating portability requirements from wire capacity requirements.
Solution Approach 2:
The de-reeling arm serves as an intermediary mechanism between the large stationary wire spool and the portable spool gun. It automatically feeds wire from the large spool to the gun, eliminating the need for manual spool changes while maintaining gun portability. The intermediary device enables continuous wire supply without requiring the gun itself to carry large wire reserves.
2Loss of time
If a large wire spool is used directly, then wire replacement frequency is reduced, but the spool gun weight increases and portability is compromised
Solution Approach 1:
The system separates wire storage function from welding application function. The large wire spool remains stationary and fixed, while the spool gun remains lightweight and portable. The de-reeling arm connects these two segments, allowing the gun to access wire from the large spool without carrying the spool itself, thus maintaining portability while reducing wire replacement frequency.
Solution Approach 2:
The de-reeling arm acts as an intermediary that enables the lightweight spool gun to access wire from a large stationary spool. This mediator allows the gun to have extended wire capacity indirectly through the large spool, without the gun itself becoming heavy. The intermediary mechanism transfers wire continuously, maintaining portability while reducing downtime.
3Device complexity
If manual wire spool exchange is used, then system complexity is minimized, but labor intensity and operational efficiency decrease
Solution Approach 1:
The de-reeling arm introduces dynamic automation to the wire feeding process. It automatically adjusts and feeds wire from the large spool to the gun as welding progresses, eliminating manual intervention. This dynamic mechanism improves operational efficiency without requiring complex control systems, maintaining relative simplicity while enabling continuous operation.
Solution Approach 2:
The de-reeling arm enables the system to serve itself by automatically feeding wire from the large spool to the spool gun during welding operations. This self-service capability eliminates the need for manual wire spool exchange, reducing labor intensity and improving productivity while keeping the system relatively simple through mechanical automation rather than complex electronic controls.
Data Source
AI summary
Disclosed is a system for dispensing welding wire for a spool gun type welding torch. In particular, the disclosed system allows conversion of the spool gun type welding torch from a small wire spool (e.g., a one pound spool) to a much larger (e.g., 16 pound spool), enhancing efficiency, reducing set-up time relative to welding.