Reciprocating Welding Wire Feed With Unidirectional Motor Drive

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Solution Overview

Problem

Traditional reciprocating wire feed systems in welding processes face limitations due to high torque requirements, susceptibility to overheating, and restricted wire feed and travel speeds, which hinder productivity and accessibility in forming controlled short circuits.

Innovation Solution

A reciprocating welding wire feed system utilizing a motor that rotates in one direction to drive a toothed or expandable drive roll system, enabling rapid directional changes and oscillating motion of the welding wire, thereby reducing torque needs and enhancing wire feed efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional bi-directional motors are used to drive reciprocating wire feed, then the wire can be fed in both directions to create controlled short circuits, but the motor requires high torque to overcome inertia, is susceptible to overheating, and limits wire feed and travel speeds

Engineering Contradiction:

Improvebidirectional wire feed capabilityVSAvoidwire feed speed and travel speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Instead of using a bi-directional motor that rotates forward and backward, the invention uses a unidirectional motor that continuously rotates in one direction. The reciprocating motion is achieved through a mechanical transmission system (cam-follower mechanism) that converts the continuous rotation into oscillating wire feed motion. This inversion eliminates the need for the motor to reverse direction, reducing torque requirements and preventing overheating while maintaining bidirectional wire feed capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention replaces the direct mechanical bidirectional motor system with a unidirectional motor coupled to a cam-follower mechanical transmission system. This substitution allows the motor to operate in its optimal continuous rotation mode while the mechanical cam mechanism provides the necessary reciprocating motion, thereby improving reliability and speed performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If traditional bi-directional motors are used to drive reciprocating wire feed, then the wire can be oscillated in and out of the weld puddle, but the motor is oversized which causes weld joint accessibility issues

Engineering Contradiction:

Improvecontrolled short circuit capabilityVSAvoidmotor size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The invention inverts the approach by using a smaller unidirectional motor with a cam-follower mechanism instead of a large bi-directional motor. This allows the welding system to achieve controlled short circuits through the cam-driven reciprocating motion while the motor itself remains compact, improving accessibility to confined weld joints.

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If reciprocating wire feed is used to achieve controlled short circuits, then welding productivity can be improved, but the system requires high torque and is prone to overheating

Engineering Contradiction:

Improvewelding travel speedVSAvoidmotor overheating resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention resolves the reliability issue by inverting the motor operation from bidirectional to unidirectional. The continuous rotation of the unidirectional motor eliminates the high torque demands and heat generation associated with frequent direction reversals, while the cam-follower mechanism maintains the reciprocating wire feed motion necessary for controlled short circuits and high welding productivity.

Inventive Principle:

Principle #13The other way round (Inversion)

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

This solution allows for higher wire feed speeds, improved arc starting, reduced spatter, increased ductility, and refined weld grain, while being more compact and less prone to overheating, thus enhancing overall welding productivity and accessibility.

Implementation Method 1

a first drive roll comprising a first set of protrusions extending radially outward from the first drive roll and configured to drive a welding wire in a first linear direction and a second drive roll disposed adjacent to the first drive roll, wherein the second drive roll comprises a second set of protrusions extending radially outward from the second drive roll and configured to drive the welding wire in a second linear direction opposite the first direction

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11969836B2Reciprocating wire feed welding system and method

Publication Date: 2024.04.30 ILLINOIS TOOL WORKS INC

AI summary

A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.