Welding Wire Buffering for Retraction Without Deformation
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Solution Overview
Problem
In welding applications, especially with robotic and automated systems, the long-distance feeding of welding wire from bulk containers to the welding torch can lead to wire deformation and damage when the wire is retracted, particularly with passive slave feeders.
Innovation Solution
A welding wire supply system with a buffer mechanism that creates a free space in the wire path between the slave feeder and the master feeder, allowing the retracted welding wire to be received without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding wire is retracted from the welding torch during stopped welding operations, then the wire can be pulled back into the wire guide, but the wire becomes deformed and damaged particularly with soft welding wires such as aluminum wires
Solution Approach 1:
The patent introduces a buffer device positioned between the master feeder and the wire guide that provides a cushioning space to receive and accommodate the welding wire when it is pushed backward during retraction. This beforehand cushioning prevents the wire from being compressed or deformed in the wire guide, thereby maintaining wire integrity and preventing bird-nesting damage to soft welding wires such as aluminum wires.
2Extent of automation
If a passive slave feeder is used to push the welding wire, then the system operates automatically, but the wire is pushed backwards into the welding guide when the welding operation is stopped, causing deformation
Solution Approach 1:
The buffer device serves as an intermediary element between the passive slave feeder and the wire guide. When the welding operation stops and the wire is pushed backward by the passive feeder, the buffer acts as a mediator that absorbs the backward movement and provides a receiving space, preventing the wire from being forced into the wire guide and deformed. This allows the passive feeder to continue operating automatically without causing wire damage.
3Reliability
If the welding wire is pulled over significant distances from bulk containers positioned on the floor, then safety regulations are complied with and larger containers can be used, but the wire feeding becomes unreliable and difficult to advance
Solution Approach 1:
The patent divides the long-distance wire feeding task into two segments: the master feeder positioned close to the welding torch that performs the final precise feeding, and the slave feeder positioned close to the bulk container that performs the long-distance transport. The buffer device is positioned at the interface between these two segments to ensure smooth transition and reliable feeding, allowing the system to handle significant distances while maintaining reliability.
Data Source
AI summary
A welding wire supply system has a first wire feeder and a wire guide for guiding the welding wire to an automated welding system with a second wire feeder and a welding torch. The wire guide includes a wire buffer arranged downstream of the first wire feeder. The wire buffer is adapted for receiving an additional length of welding wire in the path of the wire guide.