Welding Rod Dispenser With Leveling and One-by-One Feed
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Solution Overview
Problem
Welding rods are difficult to access and track in fast-paced shop environments, and existing containers do not efficiently dispense rods or accommodate multiple sizes and types, leading to inefficiencies and increased costs.
Innovation Solution
A welding rod dispenser with an angled deck, rotating grabber teeth, and adjustable levelers that automatically dispenses welding rods, counts usage, and accommodates various sizes and types, featuring a motor, motion sensor, and counter for efficient and user-friendly operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If welding rods are stored in traditional containers or racks, then storage capacity is achieved, but access difficulty increases and tracking capability is lost
Solution Approach 1:
The system uses a motion sensor to automatically detect when a welding rod is needed and dispenses it without manual intervention. The counter automatically tracks each dispensed rod, eliminating the need for manual tracking and providing real-time usage information.
Solution Approach 2:
The patent replaces manual mechanical access with an automated electromechanical system. The motion sensor detects user presence or need, triggers the motor to rotate the grabber teeth, and the counter electronically tracks usage, substituting manual operations with automated sensing and control.
2Productivity
If manual dispensing is used, then device complexity is low, but productivity decreases due to time-consuming manual operations
Solution Approach 1:
The rotating grabber teeth assembly operates in periodic cycles, rotating to present individual rods for dispensing. The motor drives the rotation in discrete steps, with each rotation cycle dispensing one or more rods, creating a rhythmic automated dispensing process that increases speed while maintaining manageable complexity.
Solution Approach 2:
The rotating grabber teeth assembly acts as an intermediary mechanism between the stored rods and the user. It automatically retrieves rods from the storage deck and presents them for dispensing, mediating the interaction between the automated system and manual retrieval needs.
3Adaptability or versatility
If traditional storage containers are used, then simplicity is maintained, but adaptability to different rod sizes and types is limited
Solution Approach 1:
The leveler assembly is designed with adjustable positioning, allowing it to be moved vertically to accommodate different rod diameters. This dynamic adjustment capability enables the same device to handle various rod sizes without requiring multiple specialized containers, balancing versatility with manageable complexity.
Solution Approach 2:
The dispenser is designed as a universal system that can handle multiple types and sizes of welding rods through the adjustable leveler and standardized rotating grabber mechanism. The angled deck and grabber teeth configuration work with various rod dimensions, making the device multi-functional rather than size-specific.
4Ease of operation
If rods are stored in disorganized manner, then storage capacity is maximized, but access time increases and neatness is compromised
Solution Approach 1:
The angled deck is designed to automatically guide rods into a predetermined organized arrangement as they are placed or settle on the surface. The angle promotes natural alignment and single-file positioning, preparing the rods for efficient retrieval by the rotating grabber teeth without requiring manual organization.
Solution Approach 2:
The angled deck creates a gravitational slope that naturally directs rods into a streamlined, organized configuration. This geometric design element promotes automatic alignment and prevents chaotic stacking, maintaining order while maximizing storage efficiency and access speed.
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 dispenser ensures easy access, even dispensing, and accurate tracking of welding rods, enhancing efficiency and reducing costs by automating the process and accommodating multiple rod sizes and types.
Implementation Method 1
a motion sensor, where the welding rod dispenser is capable of dispensing a welding rod upon activation by the motion sensor
Implementation Method 2
a motor, where the rotating assembly is turned by the motor
Implementation Method 3
a deck, where the deck angles downward from back to front; Welding rods placed atop the deck may tend to slide forward under the leveler assembly
Data Source
AI summary
A welding rod dispenser comprising: a deck, where the deck angles downward from back to front; a rotating assembly located at the front of the deck, where the rotating assembly comprises grabber teeth; and a leveler assembly located atop the deck. Welding rods placed atop the deck may tend to slide forward under the leveler assembly where the leveler assembly levels them into a single layer. Individual welding rods may then be grabbed by the grabber teeth one at a time before being moved forward by the rotating assembly for retrieval by the user.