Welding Wire Feeding Device Inertia Management
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Solution Overview
Problem
Existing wire feeding devices in welding machines experience uncontrollable start and end of the welding process, leading to slack wire issues, which result in uneven welding speed and quality problems, including pitting of the welding wire.
Innovation Solution
A wire feeding device with a hub system that includes means for storing energy, allowing the stored energy to be released to pull the wire coil in the opposite direction when the welding process ends, ensuring a continuous and uniform wire feed by eliminating slack and managing the transition between welding cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire feeding mechanism stops pulling the welding wire, then the wire feeding process is completed, but the wire coil continues to rotate under the influence of moment of inertia creating slack wire
Solution Approach 1:
The brake mechanism is activated before the wire feeding mechanism stops, creating a counteracting force that prevents the wire coil from continuing to rotate under inertia. This preliminary anti-action eliminates slack wire formation and maintains consistent wire tension throughout the stopping phase.
Solution Approach 2:
The system uses feedback control where the brake mechanism responds to the stopping signal from the wire feeding mechanism. The brake is activated in response to the feeding mechanism's stop command, creating a controlled deceleration that prevents overshooting and slack wire formation.
2Productivity
If the wire feeding mechanism starts pulling the welding wire, then the wire is fed to the welding torch, but the heavy wire coil creates a discontinuity point requiring sudden force
Solution Approach 1:
The brake mechanism is deactivated before the wire feeding mechanism starts, allowing the wire coil to be lightly braked and ready for immediate acceleration. This preliminary action reduces the sudden force requirement by transitioning the coil from a braked state to a free-rolling state smoothly.
Solution Approach 2:
The brake mechanism dynamically adjusts its braking force based on the operational phase. During startup, the brake is lightly applied or deactivated to reduce initial force requirements. During operation, the brake maintains controlled tension. This dynamic adjustment smooths the force profile throughout the wire feeding cycle.
3Reliability
If a brake mechanism is used to stop the wire coil rotation, then the wire feeding is controlled, but the start and end of welding process becomes uncontrollable
Solution Approach 1:
The brake mechanism operates in periodic cycles synchronized with the wire feeding mechanism. The brake is activated during the stopping phase and deactivated during the starting phase, creating a rhythmic pattern of brake application and release that maintains control throughout the welding process cycles.
Solution Approach 2:
The brake mechanism serves as an intermediary between the wire feeding mechanism and the wire coil. It mediates the transfer of control by being activated when the feeding mechanism stops, allowing smooth transition of control responsibility and preventing loss of control during phase transitions.
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 solution ensures a smooth start and end of the welding process, maintaining constant wire tension, preventing pitting and jerking, and providing uniform welding speed, thus enhancing the overall quality of the welding process.
Implementation Method 1
a spring (13), arranged between the shaft (11) and the frame (1), for storing energy, which is created, when the wire coil (3) rotates in the unwinding direction and for releasing the stored energy, for pulling the wire coil (3) in the winding direction
Implementation Method 2
When the wire feeding mechanism stops pulling the wire, the brake mechanism (14) is returned into the starting position, wherein the hub system (2) creates a light braking force to the wire coil (3)
Implementation Method 3
there typically remains a bit of slack welding wire between the wire coil and the wire feeding mechanism, because the heavy wire coil still rolls slightly under the influence of the moment of inertia
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an arrangement and a method in a wire feeding device (L) comprising a frame (1), a hub system (2) arranged to the frame (1) for winding a wire coil (3), and a wire feeding mechanism (4) for pulling the welding wire (10) from the wire coil (3) such that the wire coil (3) rotates in the unwinding direction and for feeding the welding wire (10) through the wire feeding mechanism (4) to a welding torch (5). In the method, in the wire feeding starting stage, the wire feeding mechanism (4) pulls the welding wire (10) into motion and, in the wire feeding stopping stage, the wire feeding mechanism (4) stops pulling the welding wire (10). The hub system (2) comprises means for storing energy, said means for storing energy being adapted to store energy as the wire feeding mechanism (4) starts to pull the welding wire (10) from the wire coil (3) in the unwinding direction such that, when the wire feeding mechanism (4) stops pulling the welding wire (10), the stored energy is adapted to be released, pulling the wire coil (3) in the winding direction, which is the opposite direction in relation to the unwinding direction.