Welding Wire Straightening Roller Layout for Flux-Cored Targetability
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Solution Overview
Problem
Existing welding-wire-straightening apparatuses, particularly those with small diameter rollers, fail to maintain targetability when used with flux containing wires, leading to wire misalignment and reduced welding quality due to deformation and local loads applied during the straightening process.
Innovation Solution
A welding-wire-straightening apparatus with two sets of roller groups, each comprising multiple rollers with diameters of 20 mm or less, arranged at specific intervals to achieve entrance and exit deformation amounts within defined ranges, ensuring effective straightening and minimizing local loads, thereby improving targetability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If small diameter straightening rollers (20 mm or less) are used, then the size of the straightening apparatus decreases, but the targetability of flux containing wire deteriorates due to deformation and local loads
Solution Approach 1:
The patent applies parameter changes by optimizing the arrangement interval L between rollers to 11.5 mm or more, which is a specific parameter value that prevents local load concentration on flux-containing wire while maintaining compact apparatus size. This parameter optimization resolves the contradiction between small roller diameter and wire targetability.
Solution Approach 2:
The patent divides the straightening function into multiple rollers (n≥4) arranged in sequence, where each roller contributes to gradual wire straightening. This segmentation allows the use of small diameter rollers while distributing the straightening action to prevent deformation of flux-containing wire.
2Volume of moving object
If multiple rollers with small arrangement interval are used, then the apparatus size decreases, but wire misalignment occurs due to excessive local loads
Solution Approach 1:
The patent changes the parameter of arrangement interval L to 11.5 mm or more, which is the critical value that prevents wire misalignment while maintaining compact apparatus size. This parameter optimization ensures reliable wire alignment without excessive apparatus dimensions.
3Manufacturing precision
If the straightening apparatus is disposed on the robot arm, then the targetability near arc point is improved, but the robot movement range is restricted due to apparatus size
Solution Approach 1:
The patent optimizes the arrangement interval parameter L to 11.5 mm or more, which enables the straightening apparatus to achieve effective wire straightening in a compact configuration. This allows the apparatus to be mounted on the robot arm without excessively restricting robot movement range while maintaining good targetability near the arc point.
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 apparatus effectively straightens welding wires, preventing misalignment and enhancing targetability, even with flux containing wires, while maintaining a compact size to avoid restricting robot movement and ensuring stable welding quality.
Implementation Method 1
the n rollers (n is an integer of 4 or more) bend the welding wire alternately in opposite directions and straighten a curl of the welding wire
Implementation Method 2
an entrance wire deformation amount εin that is calculated by using a numerical formula of εin={2t(δin+t)/Lin2}×100 ranges from 0.6 to 1.0 (%)
Data Source
AI summary
In each of roller groups, multiple straightening rollers include a first roller, a second roller, . . . , an n-th roller in this order in a direction in which a welding wire passes through, and the n rollers (n is an integer of 4 or more) bend the welding wire alternately in opposite directions and straighten a curl of the welding wire. The n rollers are arranged such that an entrance wire deformation amount εin calculated by using a numerical formula of εin={2t(δin+t)/ Lin2}×100 ranges from 0.6 to 1.0 (%), and an exit wire deformation amount tout calculated by using a numerical formula of εout=2t(δout+t)/Lout2}×100 ranges from 0.0 to 0.3 (%) . Diameters 2r of the multiple straightening rollers are 20 mm or less. An arrangement interval L of the multiple straightening rollers is 11.5 mm or more.