Welding Wire Feeder Module for Real-Time Consumption Tracking
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Solution Overview
Problem
Automated welding installations, such as welding robots, lack real-time monitoring and recording of welding wire consumption, leading to inefficiencies in wire usage and increased changeover downtime due to the inability to track wire length and weight accurately.
Innovation Solution
A module comprising a sensor to detect welding wire feed motion, a processor to store data, and an output device to record and provide information on wire usage, including speed, length, and remaining wire quantity, with an optional touch display for operator input and a wireless data connection to assist the feeding system, ensuring precise measurement and alerting operators when wire replacement is needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If welding wire is stored in bulk packs at a distance from the welding robot, then safety and handling are improved, but real-time monitoring of wire consumption becomes difficult
Solution Approach 1:
A sensor wheel acts as an intermediary between the welding wire and the control system. The sensor wheel contacts the welding wire and converts its rotational motion into electrical signals that are processed to determine wire feed length, enabling remote monitoring without requiring the wire storage to be nearby
Solution Approach 2:
The mechanical feeding system is supplemented with an electronic sensing and data processing system. Instead of relying solely on mechanical wire feeding, the patent introduces electronic sensors and processors that convert mechanical wire movement into digital data for remote monitoring and analysis
2Productivity
If the feeding system uses actively driven wheels to advance welding wire, then wire delivery is ensured, but measurement precision of wire feed speed deteriorates due to friction
Solution Approach 1:
The feeding function is segmented into two separate components: an active feeding wheel that provides the driving force to advance the wire, and a passive sensor wheel that only measures wire speed without applying driving force. This segmentation allows each component to perform its specific function optimally without interfering with the other
Solution Approach 2:
The passive sensor wheel serves as an intermediary measurement device that contacts the welding wire to detect its feed speed. Because it is not actively driven, it does not introduce friction that would affect measurement accuracy, yet it still enables precise speed detection through its rotational motion
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 accurate tracking of welding wire consumption, reducing changeover downtime by allowing operators to plan inventory and optimize production, improving productivity and efficiency by providing real-time data on wire usage and robot performance.
Implementation Method 1
the sensor comprises a wheel which is adapted for contacting welding wire. Due to the frictional contact between the wheel and the welding wire, the speed of rotation of the wheel precisely corresponds to the speed with which the welding wire is being advanced
Implementation Method 2
an encoder is preferably provided which senses the rotation of a wheel. The signal of the encoder then is indicative of the speed with which the welding wire advances
Implementation Method 3
A contact-free sensor can use one of acoustic waves and electromagnetic waves for sensing a welding wire feed motion
Implementation Method 4
A contact-free sensor can use one of acoustic waves and electromagnetic waves for sensing a welding wire feed motion
Data Source
AI summary
A module for controlling welding parameters and a method for operating a welding wire feeder is disclosed, with the feeder having a motor, a feeding wheel driven by the motor, a control which controls operation of the motor, an operator interface adapted for allowing an operator to input data which is being used by the control.