Wearable Wire Feeder for Remote Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional portable welding systems, including wire feeders, are often bulky, heavy, and difficult to maneuver, especially in remote or hard-to-reach locations, requiring additional support or assistance due to their stationary design and long conduit runs, which increases cost and complexity.
Innovation Solution
A wearable wire feeder system with a support for welding wire spool and a motor drive, integrated with a portable engine-driven welding system, allowing the feeder to be mounted on the user for hands-free operation and reducing the length and weight of cables, thus enabling more flexible and efficient welding in remote locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional wire feeders are designed as stationary devices, then they can provide stable wire feeding control, but they cannot be moved to remote locations or different work areas
Solution Approach 1:
The system divides the wire feeding function into two separate components: a portable wireless-controlled wire feeder that can be moved to remote locations, and a stationary power unit that contains the control circuitry. The portable feeder communicates wirelessly with the power unit, allowing the wire feeder to be relocated without moving the complex control systems.
2Ease of operation
If wire feeders are integrated into the welding torch, then they can provide compact design, but they result in a bulky and heavy torch that is difficult to hold and maneuver
Solution Approach 1:
The wire feeder mechanism is extracted from the welding torch and placed in a separate portable unit. The torch becomes a lightweight handheld device for welding operations, while the wire feeder is contained in a separate carrier that can be worn on the body, eliminating the weight and bulk from the torch itself.
3Adaptability or versatility
If conventional portable wire feeders are made compact for portability, then they can be moved more easily, but they become too heavy or bulky to move effectively in difficult terrain
Solution Approach 1:
The system transitions from horizontal portability (moving the entire wire feeder across terrain) to vertical portability (wearing the wire feeder on the body). The portable wireless-controlled wire feeder is designed to be worn on a carrier such as a belt or harness, allowing the user to carry it easily up stairs, ladders, and steep inclines without needing to drag or lift heavy equipment.
4Length of stationary object
If wire feeders require long conduit runs to reach remote locations, then they can maintain connection to the power source, but they require more robust and expensive drive mechanisms
Solution Approach 1:
The system replaces the mechanical conduit connection with a wireless communication system. The portable wireless-controlled wire feeder receives control signals wirelessly from the power unit, eliminating the need for long physical conduit runs and the associated robust mechanical drive mechanisms required to push wire through extended conduits.
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
The wearable wire feeder system allows for more freedom and efficiency in welding operations by reducing the weight and bulk of equipment, enabling welding in small or hard-to-reach areas without the need for additional support, and lowering manufacturing costs through simplified design and reduced control circuitry.
Implementation Method 1
a motor drive for driving the spool in response to a control signal
Implementation Method 2
a welding torch... controllable to generate a signal... for a welding operation
Data Source
AI summary
A welding system is provided that includes a wearable wire feeder having a wire drive motor that is responsive to a control signal received directly from a power unit. Another welding system is provided that includes a wearable wire feeder that is configured to couple to a constant voltage power unit and does not include a voltage sensor. Another welding system is provided that includes a power unit, a wearable wire feeder separate from the power unit, a cable extending directly from the power unit to the wearable wire feeder and a welding torch coupled to and separate from the wire feeder. A method is provided that includes receiving a control signal from a power unit at a wearable wire feeder and driving a welding wire from the wearable wire feeder to a welding torch in response to the control signal, wherein the wearable wire feeder is separate from the torch.