Welding Wire Straightening Rolls That Limit Damage and Flux Leakage
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Solution Overview
Problem
Conventional straightening devices for welding wire often damage the wire due to excessive pressing, cause flux leakage in flux cored wires, and lead to the removal of surface plating or lubricant, resulting in poor wire straightening and increased risk of 'wire run-out' during welding.
Innovation Solution
The straightening device employs small-diameter straightening rolls with a roll radius to wire diameter ratio between 1.2 and 6, and a non-adjustable configuration to minimize pressing force and contact area, reducing friction and preventing wire damage, while ensuring effective straightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pressing depth of the rolls is increased to straighten the welding wire, then the straightening effect is improved, but the welding wire is damaged and flux leaks in flux cored wire
Solution Approach 1:
The straightening device is divided into multiple straightening units (at least three), with each unit containing multiple rolls arranged in zigzag. Each unit applies a portion of the total pressing force, distributing the straightening action across multiple stages rather than using excessive force from a single unit, thereby achieving effective straightening while minimizing wire damage and flux leakage.
Solution Approach 2:
The rolls in each straightening unit are arranged in a zigzag pattern with specific orientations (first unit: 0-30 degrees, second unit: 30-60 degrees, third unit: 60-90 degrees). This localized variation in roll orientation creates different pressing zones that progressively straighten the wire without concentrating excessive force in a single location, preventing wire damage while maintaining straightening effectiveness.
2Manufacturing precision
If the pressing amount of each roll is increased to straighten the welding wire, then the straightening effect is improved, but the welding wire moves away in the groove to be twisted
Solution Approach 1:
The straightening action is segmented into multiple units, each applying a controlled portion of the pressing force. This prevents any single roll group from applying excessive force that would cause the wire to move out of the groove and twist, while the cumulative effect of all units achieves the desired straightening.
Solution Approach 2:
The pressing force is dynamically distributed across multiple straightening units with progressively oriented rolls. The first unit applies force at 0-30 degrees, the second at 30-60 degrees, and the third at 60-90 degrees, creating a progressive straightening action that guides the wire through the grooves without causing it to jump out and twist.
3Manufacturing precision
If the contact length between the welding wire and each roll increases, then the straightening effect is improved, but plating on the surface comes off or lubricant is removed
Solution Approach 1:
The total contact length between the wire and rolls is segmented across multiple straightening units. Each unit provides necessary contact for straightening, but the distributed arrangement reduces the cumulative contact area compared to a single long-contact straightener, thereby minimizing friction that would otherwise remove plating or lubricant while still achieving effective straightening.
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 effectively suppresses harmful influences on the welding wire, preventing damage and maintaining the integrity of surface coatings, thereby ensuring high-quality wire straightening and reducing 'wire run-out' during welding.
Implementation Method 1
Bend in a plastic deformation region is applied to a wire by a first roll group on a wire entrance side
Implementation Method 2
bend in an elastically deformation region is applied to the wire by a final roll group on an exit side
Data Source
Figure 1~2A
Figure 2B~3
Figure 4
AI summary
A straightening device for welding wire (1) is provided with two sets of roll groups (13a), (13b) having a plurality of straightening rolls (12) with which bends in a welding wire (W) are straightened by passing the welding wire (W) through the two sets of roll groups (13a), (13b). The plurality of straightening rolls (12) configuring the roll groups (13a), (13b) are arranged at a predetermined arrangement interval along a passing direction of the welding wire (W) in such a way as to face with each other across a straightening path (T) along which the welding wire (W) passes, and the two sets of roll groups (13a), (13b) are arranged so that the directions in which they face across the straightening path (T) are different from each other. By configuring the straightening rolls (12) by small-diameter rollers, adverse effects on the welding wire (W) are suppressed, and the welding wire (W) is straightened finely.