De-coiling Cone with Weighted Legs for Weld Wire Dispensing
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Solution Overview
Problem
Tangles frequently occur in weld wire containers, particularly with larger diameter or stiffer wire alloys, due to twist induced by the feeding system, causing the wire to get caught on the de-coiling cone and leading to feeding interruptions during welding operations.
Innovation Solution
A de-coiling cone design with an inner ring, an outer ring, and radially extending legs, including a backwardly bent leg portion that increases the cone's weight and allows it to rest directly on the weld wire coil without an intermediate member, preventing tangles by ensuring smooth wire feeding and maintaining contact with the coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a typical de-coiling cone with three concentric rings and legs is used, then wire feeding is facilitated, but wire tangles occur when wire moves up above the cone between the cone and inner liner
Solution Approach 1:
The de-coiling cone is designed with a weighted structure that preliminarily positions itself directly on the wire coil before feeding begins. The backwardly bent leg portions and extended radial sections ensure the cone maintains preliminary contact with the wire, preventing the wire from rising above the cone and tangling during operation.
2Reliability
If an intermediate cardboard ring is used between the de-coiling cone and wire coil, then wire support is provided, but device complexity and potential tangling points increase
Solution Approach 1:
The intermediate cardboard ring is completely removed from the system. The de-coiling cone is redesigned to directly support the wire coil through its weighted structure with backwardly bent legs, eliminating the intermediate component and its associated complexity and potential failure points.
Solution Approach 2:
The functions of the de-coiling cone and intermediate cardboard ring are merged into a single integrated structure. The de-coiling cone itself provides both the feeding guidance function and the wire support function through its weighted design that rests directly on the wire coil.
3Ease of manufacture
If the de-coiling cone is lightweight, then ease of installation is improved, but the cone cannot maintain stable contact with the wire coil, causing tangles
Solution Approach 1:
The weight parameter of the de-coiling cone is increased through the addition of backwardly bent leg portions and extended radial sections. This parameter change ensures the cone maintains stable contact with the wire coil during feeding operations, preventing the wire from rising above the cone and tangling while remaining manufacturable.
Data Source
AI summary
A system for dispensing weld wire comprises a container including walls and inside corners, a coil of weld wire within the container, and a de-coiling cone on the weld wire. The coil includes inner and outer circumferences, and the de-coiling cone includes an inner ring smaller than the inner circumference of the coil, an outer ring larger than the inner circumference and smaller than the outer circumference of the coil, and a plurality of legs extending radially outward from the inner ring to positions adjacent respective inside corners of the container. Each leg includes a first leg portion connecting the inner and outer rings, a second leg portion extending radially outwardly from the first leg portion, and a backwardly bent leg portion adjacent a corresponding inside corner of the container.