U.S. patent application number 11/965813 was filed with the patent office on 2008-07-03 for wire dispensing system.
This patent application is currently assigned to Elco Enterprises, Inc.. Invention is credited to Edward L. Cooper.
Application Number | 20080156925 11/965813 |
Document ID | / |
Family ID | 39580570 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080156925 |
Kind Code |
A1 |
Cooper; Edward L. |
July 3, 2008 |
Wire Dispensing System
Abstract
A wire dispensing system for continuously dispensing wire from
wire coils to a welding site. The system includes a wire feeder
mounted above the wire coils on a frame and a wire transfer arm
which moves between the wire coils as one wire coil is depleted and
the other wire coil is started.
Inventors: |
Cooper; Edward L.;
(Clarklake, MI) |
Correspondence
Address: |
FRASER TREBILCOCK DAVIS & DUNLAP, P.C.
124 WEST ALLEGAN STREET, SUITE 1000
LANSING
MI
48933
US
|
Assignee: |
Elco Enterprises, Inc.
Jackson
MI
|
Family ID: |
39580570 |
Appl. No.: |
11/965813 |
Filed: |
December 28, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60883258 |
Jan 3, 2007 |
|
|
|
Current U.S.
Class: |
242/559.3 ;
242/559; 242/564.3 |
Current CPC
Class: |
B65H 57/12 20130101;
B65H 57/18 20130101; B23K 9/133 20130101; B65H 49/12 20130101 |
Class at
Publication: |
242/559.3 ;
242/559; 242/564.3 |
International
Class: |
B65H 19/10 20060101
B65H019/10; B65H 16/00 20060101 B65H016/00 |
Claims
1. A weld wire dispensing system for continuously feeding wire from
wire coils to a welding site, which comprises: a) a frame for
positioning the wire coils; and b) a wire feeder mounted on the
frame and spaced apart from the wire coils for pulling wire from
the wire coils and pushing wire to the welding site.
2. The system of claim 1 wherein the frame has a center post
configured to be positioned between the wire coils and wherein the
wire feeder is mounted on the center post.
3. The system of claim 1 wherein the frame has a wire transfer arm
configured to be positioned between the wire coils and the wire
feeder and wherein the wire transfer arm is configured to pivot
from a position adjacent one of the wire coils to a position
adjacent another one of the wire coils.
4. The system of claim 2 wherein a wire transfer arm is pivotably
mounted on the center post between the wire coils and the wire
feeder and wherein when the wire coils are positioned in the frame,
the wire transfer arm is configured to pivot from a position
adjacent one of the wire coils to a position adjacent another one
of the wire coils.
5. The system of claim 4 wherein the wire transfer arm extends
outward from the center post in a direction towards the wire coils,
wherein a guide conduit for guiding the wire extends between the
wire coils and the wire feeder, wherein the guide conduit is
attached to the wire transfer arm spaced apart from the center post
and wherein the positioning of the guide conduit on the wire
transfer arm automatically pivots the wire transfer arm from
adjacent one of the wire coils to adjacent the other one of the
wire coils when one of the wire coils is depleted and the wire is
provided from the other one of the wire coils.
6. The system of claim 3 wherein a guide conduit having opposed
ends and configured to house the wire is connected to the wire
transfer arm, wherein one end of the guide conduit is adjacent the
wire feeder and the other end of the guide conduit is adjacent one
of the wire coils and wherein when the one of the wire coils is
depleted, the wire transfer arm pivots to move the other end of the
guide conduit adjacent another one of the wire coils.
7. The system of claim 1 wherein the frame includes drums for
containing the wire coils, wherein the drums have tops and wherein
the tops of the drums have slots.
8. The system of claim 1 wherein the wire feeder moves the wire to
the welding site at a constant rate.
9. The system of claim 1 wherein a power source for the wire feeder
is a hydraulic motor.
10. The system of claim 1 wherein a power source for the wire
feeder is an electric motor.
11. A wire dispensing system for continuously moving wire to a
welding site, which comprises: a) a first wire coil having a first
end and a second end; b) a second wire coil having a first end and
a second end wherein the first end of the second wire coil is
configured to be connected to the second end of the first wire
coil; and c) a wire feeder spaced apart from the first and second
wire coils and configured to receive wire from the first or second
wire coil wherein in operation the wire feeder pulls the wire from
the first or second wire coil and pushes the wire to the welding
site.
12. The system of claim 11 wherein the first and second wire coils
are held in position by a frame and wherein the wire feeder is
mounted on the frame positioned between the first and second wire
coils.
13. The system of claim 12 wherein a wire transfer arm is pivotably
mounted on the frame and is configured to move between the first
and second wire coils.
14. The system of claim 13 wherein the wire transfer arm is
positioned between the wire coil and the wire feeder.
15. The system of claim 14 wherein the wire transfer arm is
configured to be connected to the wire and guide the wire to the
wire feeder, wherein the wire extends from the first wire coil to
the wire transfer arm to and through the wire feeder to the welding
site and wherein when the first wire coil is depleted, the wire
transfer arm pivots so that the wire extends from the second wire
coil to the wire transfer arm to and through the wire feeder to the
welding site.
16. The system of claim 14 wherein a guide conduit having opposing
ends and configured to receive the wire is connected to the wire
transfer arm, wherein one end of the guide conduit is adjacent the
wire feeder and the other end of the guide conduit is adjacent the
first wire coil and wherein when the first wire coil is depleted,
the wire transfer arm pivots to move the other end of the guide
conduit adjacent the second wire coil.
17. The system of claim 11 wherein the first and second wire coils
are positioned in first and second drums, wherein the first and
second drums have tops with slots.
18. The system of claim 17 wherein the tops of the drums are curved
so that when the wire is moved from the drums, the wire moves along
a curved inner surface of the tops which reduces friction on the
wire.
19. The system of claim 17 wherein the first end of the second wire
coil extends out of the second drum through the slot in the top,
wherein the second end of the first wire coil extends out of the
first drum through the slot in the top and wherein the first wire
coil and the second wire coil are connected together at a point
between the first and second drums.
20. A wire dispensing system for continuously dispensing wire from
wire coils to a welding site, which comprises a) a pair of drums,
each drum configured to hold one wire coil; b) a frame for
positioning the drums in a side-by-side arrangement having a center
post positioned between the drums and extending upward beyond a top
of the drums; c) a wire feeder mounted on the center post above the
top of the drums; d) a first guide conduit extending between the
top of the drums and the wire feeder; and e) a second guide conduit
extending from the wire feeder toward the welding site, wherein the
wire feeder pulls the wire through the first guide conduit and
pushes the wire through the second guide conduit to the welding
site.
21. The system of claim 20 wherein the wire feeder has an inlet
guide and an outlet guide, wherein the first guide conduit is
connected to the inlet guide of the wire feeder and extends toward
the drums and wherein the second guide conduit is connected to the
outlet guide of the wire feeder and extends toward the welding
site.
22. The system of claim 21 wherein a wire transfer arm is pivotably
mounted on the frame between the wire feeder and the drums, wherein
the first guide conduit has opposed first and second ends with the
first end connected to the inlet guide of the wire feeder, wherein
the first guide conduit is attached to the wire transfer arm and
wherein the wire transfer arm moves the second end of the first
guide conduit from adjacent one drum to adjacent the other drum
when the wire coil in the one drum is depleted and the wire is
provided from the other drum.
23. A system for feeding wire from a wire coil to a welding site
which comprises: a) a drum for holding the wire coil having a top
with an opening; and b) a wire feeder mounted on the top of the
drum adjacent the opening for pulling wire from the wire coil out
of the drum and pushing the wire to the welding site.
24. The system of claim 23 wherein the top of the drum has a cone
shape having a rounded apex, and wherein the opening is in the apex
of the top.
25. The system of claim 24 wherein the wire feeder has an inlet and
an outlet and wherein the inlet of the wire feeder is positioned
over the opening in the top.
26. The system of claim 25 wherein a support disk is provided
adjacent the opening for supporting the wire feeder.
27. The system of claim 25 wherein the opening has an inlet probe
and wherein the inlet of the wire feeder is secured on the inlet
probe to position the wire feeder on the top of the drum and
wherein wire from the wire coil extends through the inlet probe
into the inlet of the wire feeder and out the outlet of the wire
feeder to the welding site.
28. A method for continuously providing welding wire to a welding
site, which comprises the steps of: a) providing at least two wire
coils; b) providing a wire feeder; c) feeding the wire from one of
the wire coils through the wire feeder to the welding site; d)
activating the wire feeder so that the wire feeder pulls wire from
one of the wire coils and pushes the wire to the welding site; e)
connecting an end wire from one of the wire coils to a start wire
of the other one of the wire coils; and f) switching from one of
the wire coils to the other of the wire coils when one of the wire
coils is depleted, wherein as the wire is dispensed from one of the
wire coils and the end wire of the wire coil is reached, the wire
feeder continues to pull on the wire so that the start wire of the
other one of the wire coils is moved through the wire feeder so
that the wire is provided from the other one of the wire coils and
wire is continuously provided to the welding site.
29. The method of claim 28 wherein a wire transfer arm is
positioned between the wire coils and the wire feeder, wherein the
wire transfer arm guides the wire from the wire coil to the wire
feeder, wherein before step (f), the wire transfer arm is adjacent
one of the wire coils, and wherein in step (f), when the wire from
one of the wire coils reaches the end wire, the wire transfer arm
pivots to adjacent the other one of the wire coils.
30. The method of claim 28 wherein in step (f), when one of the
wire coils is depleted, a new wire coil is added and steps (e) and
(f) are repeated to connect an end wire from the other one of the
wire coils to a start wire of the new wire coil and to move the
wire from the new wire coil when the other one of the wire coils is
depleted.
31. The method of claim 28 wherein a guide conduit is provided
between the wire feeder and the welding site, wherein the guide
conduit has curves and wherein in step (d), when the wire feeder
pushes the wire to the welding site, the wire is pushed toward an
outside of the curves to reduce friction on the wire.
32. The method of claim 28 wherein in step (d), when the wire
stops, the wire feeder stalls and stops pushing the wire.
33. The method of claim 32 wherein in step (d), when the wire
begins moving, the wire feeder automatically activates to push the
wire to the welding site.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/883,258, filed Jan. 3, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] The present invention relates to a wire dispensing system
for use with welding wire. In particular, the present invention
relates to a wire dispensing system which enables continuous
dispensing of wire from a wire coil to a welding site. The present
invention also relates to a wire dispensing system which enables
movement of the wire through a welding wire guide system where the
wire coil is a long distance from the welding site.
BRIEF SUMMARY OF THE INVENTION
[0004] A wire dispensing system for continuous dispensing of wire
from wire coils to a welding site. The system enables switching
from a depleted wire coil to a new wire coil without having to stop
the system or reload the system with the new wire. The system
includes a frame and a wire feeder. The frame is used to position
the wire coils in a side by side relationship and to mount the wire
feeder above the wire coils. In one (1) embodiment, the wire coils
are mounted in drums. The drums have a top with a slot which allows
for dispensing of the wire from the drums and for automatic
switching from one drum to the adjacent drum. The frame also
includes a wire transfer arm spaced between the drums and the wire
feeder. The wire transfer arm is pivotably mounted so as to be able
to pivot from a position over one of the drums to a position over
the adjacent drum. The wire transfer arm extends outward from the
frame toward the drums and away from the wire feeder. The wire is
attached to the wire transfer arm spaced apart from the center post
of the frame and the wire feeder. The system can also be provided
with guide conduits which extend from the drums to the inlet of the
wire feeder and from the outlet of the wire feeder to the welding
site. The guide conduits help to protect the wire and to correctly
position the wire. The wire from the first coil is fed through the
first guide conduit to the wire feeder through the wire feeder to
the second guide conduit. The wire feeder is then activated to move
the wire through the second guide conduit to the welding site. The
wire feeder pulls the wire from the wire coil and pushes the wire
to the welding site. The second end of the first wire coil is
connected to the first end of the second wire coil. Thus, when the
first wire coil is depleted, the wire is automatically dispersed
from the second wire coil. As the dispensing of the wire moves from
the first wire coil to the second wire coil, the wire pulls on the
wire transfer arm and pivots the wire transfer arm from over the
first wire coil to over the second wire coil to ensure that the
wire continuously moves without interruption to the wire feeder and
to the welding site. In a second embodiment, the wire feeder is
mounted directly on the top of the drum. In this embodiment, the
top has a cone shape with an opening in the apex of the cone.
[0005] The present invention relates to a weld wire dispensing
system for continuously feeding wire from wire coils to a welding
site, which comprises a frame for positioning the wire coils and a
wire feeder mounted on the frame and spaced apart from the wire
coils for pulling wire from the wire coils and pushing wire to the
welding site.
[0006] Further, the present invention relates to a wire dispensing
system for continuously moving wire to a welding site, which
comprises a first wire coil having a first end and a second end, a
second wire coil having a first end and a second end wherein the
first end of the second wire coil is configured to be connected to
the second end of the first wire coil, and a wire feeder spaced
apart from the first and second wire coils and configured to
receive wire from the first or second wire coil wherein in
operation the wire feeder pulls the wire from the first or second
wire coil and pushes the wire to the welding site.
[0007] Still further, the present invention relates to a wire
dispensing system for continuously dispensing wire from wire coils
to a welding site, which comprises a pair of drums, each drum
configured to hold one wire coil, a frame for positioning the drums
in a side-by-side arrangement having a center post positioned
between the drums and extending upward beyond a top of the drums, a
wire feeder mounted on the center post above the top of the drums,
a first guide conduit extending between the top of the drums and
the wire feeder, and a second guide conduit extending from the wire
feeder toward the welding site, wherein the wire feeder pulls the
wire through the first guide conduit and pushes the wire through
the second guide conduit to the welding site.
[0008] Further still, the present invention relates to a system for
feeding wire from a wire coil to a welding site which comprises a
drum for holding the wire coil having a top with an opening and a
wire feeder mounted on the top of the drum adjacent the opening for
pulling wire from the wire coil out of the drum and pushing the
wire to the welding site.
[0009] Still further, the present invention relates to a method for
continuously providing welding wire to a welding site, which
comprises the steps of providing at least two wire coils, providing
a wire feeder, feeding the wire from one of the wire coils through
the wire feeder to the welding site, activating the wire feeder so
that the wire feeder pulls wire from one of the wire coils and
pushes the wire to the welding site, connecting an end wire from
one of the wire coils to a start wire of the other one of the wire
coils, and switching from one of the wire coils to the other of the
wire coils when one of the wire coils is depleted, wherein as the
wire is dispensed from one of the wire coils and the end wire of
the wire coil is reached, the wire feeder continues to pull on the
wire so that the start wire of the other one of the wire coils is
moved through the wire feeder so that the wire is provided from the
other one of the wire coils and wire is continuously provided to
the welding site.
[0010] The substance and advantages of the present invention will
become increasingly apparent by reference to the following drawings
and the description.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0011] FIG. 1 is side view of the wire dispensing system 10 of the
present invention showing the frame 12, the wire feeder 24 and the
drum 20.
[0012] FIG. 2 is a front view of the wire dispensing system 10
showing the drums 18 and 20, the frame 12 and the wire feeder
24.
[0013] FIG. 2A is a schematic top view showing the slots 23 in the
tops 19 of the drums 18 and 20.
[0014] FIG. 3 is a top view of the wire feeder 24 in the operating
position with the wire 100 loaded through the wire feeder 24.
[0015] FIG. 4 is a top view of the wire feeder 24 without the drive
roller 24 and the follower roller 38 showing the handle 42 in the
open locked position with the handle 42 in the closed, unlocked
position in phantom.
[0016] FIG. 5 is a top view of the wire feeder 24 without the drive
roller 24 and the follower roller 38 with the bail 40 in the open,
load position.
[0017] FIG. 6 is a front view of the drum 218 and top 219 of a
second embodiment of the wire dispensing system 210.
[0018] FIG. 7 is a front, partial view of the top 219 of the drum
218 of the second embodiment showing the wire feeder 224 mounted on
the inlet probe 227.
DETAILED DESCRIPTION OF THE INVENTION
[0019] All patents, patent applications, government publications,
government regulations, and literature references cited in this
specification are hereby incorporated herein by reference in their
entirety. In case of conflict, the present description, including
definitions, will control.
[0020] FIGS. 1 and 2 show the wire dispensing system 10 of the
present invention. The wire dispensing system 10 enables continuous
dispensing of welding wire 100 from wire coils 102 and 104 to a
welding site (not shown). The wire dispensing system 10 includes a
frame 12, a wire transfer arm 22, a wire feeder 24, and guide
conduits 28 and 30. The system 10 also includes drums 18 and 20
which contain the wire coils 102 and 104. However, it is understood
that the system 10 may be used with or without a container for the
wire coils 102 and 104 and that any means for containing the wire
coils 102 and 104 well known in the art may be used. The frame 12
allows for positioning a pair of wire coils 102 and 104 in first
and second drums 18 and 20 in a side by side position. In one (1)
embodiment, the frame 12 includes horizontal side arms 14 and a
center arm 16 which form side-by-side stalls or openings which
enable the wire coils 102 and 104 to be positioned adjacent to each
other with the center arm 16 positioned between the wire coils 102
and 104. In another embodiment (not shown), the frame includes
front and back side arms and front and back center arms which
allows for the positioning of four (4) wire coils. The frame 12
includes a vertical center post 21 which extends upward beyond the
top end of the drums 18 and 20. The vertical center post 21 is
positioned between the drums 18 and 20. In one (1) embodiment, the
frame 12 is constructed of aluminum. However, it is understood that
the frame 12 can be constructed of any durable material.
[0021] Each of the drums 18 and 20 has a top or dome 19 positioned
on the open, top end of each of the drums 18 and 20. The tops 19
are essentially identical. In one (1) embodiment, the tops 19 have
a rounded shape. In one (1) embodiment, the top 19 is plastic. In
one (1) embodiment, the outer edge of the top 19 has a shape
similar to the shape of the drum 18 and 20, for example round,
square or octagon. In one (1) embodiment, the top 19 completely
covers the open top end of the drum 18 and 20. Each top 19 has a
slot 23 having first and second ends 23A and 23B (FIG. 2A). The
first end 23A of the slot 23 is adjacent the center of the top 19
and the drum 18 or 20. The second end 23B of the slot 23 is
adjacent the outside edge or rim of the top 19 and the drum 18 or
20. In one (1) embodiment, the shape of the slot 23 from the center
to the edge is arcuate similar to the path of the second end 22B of
the wire transfer arm 22 as the transfer arm 22 moves from over the
first drum 18 to over the second drum 20. In one (1) embodiment,
the slot 23 extends from the center of the drum 18 in a direction
toward the adjacent drum 20 and away from the center post 21. In
one (1) embodiment, the slots 23 are a straight line from the
center of the drum 18 and 20 to essentially the rim of the drums 18
and 20. The slots 23 of the tops 19 of each adjacent drum 18 or 20
are mirror images of each other. In one (1) embodiment, a bridge is
provided extending between the second ends 23B of the slots 23
adjacent the edges of the drums 18 or 20.
[0022] A wire transfer arm 22 is pivotably mounted on the center
post 21 spaced apart from and above the drums 18 and 20. The wire
transfer arm 22 has opposed first and second ends 22A and 22B with
the first end 22A pivotably mounted on the center post 21. In one
(1) embodiment, the wire transfer arm 22 is essentially
perpendicular to the center post 21 and extends outward from the
center post 21 in a direction essentially toward the drums 18 and
20 and the wire coils 102 and 104. The wire transfer arm 22 is able
to be pivoted between the side-by-side wire coils 102 and 104 and
drums 18 and 20 (FIG. 2). The second end 22B of the wire transfer
arm 22 opposite the center post 21 is positioned over one of the
drums 18 and 20 essentially at the point where the wire 100 exits
the drum 18 or 20. In one (1) embodiment, the second end 22B of the
wire transfer arm 22 is directly over the center of the drum 18 or
20.
[0023] The wire feeder 24 is mounted on the center post 21 spaced
above the wire transfer arm 22 and the drums 18 and 20. The wire
feeder 24 is intended to be essentially permanently mounted on the
frame 12. In one (1) embodiment, where the frame is used to
position four (4) drums, a second wire feeder is mounted on the
center post on a side opposite the first wire feeder 24. In this
embodiment, each wire feeder services a pair of drums and a pair of
wire coils. The wire feeder 24 has an inlet 24A through which the
wire 100 enters the wire feeder 24 and an outlet 24B through which
the wire 100 exits the wire feeder 24 (FIGS. 3 to 5). In one (1)
embodiment the wire feeder 24 is similar to wire feeder described
in U.S. Pat. No. 6,286,748 which is incorporated herein by
reference in its entirety. However, it is understood that any
device for moving wire 100 can be used. In one (1) embodiment, the
wire feeder 24 includes a drive gear 34 having a drive roller 34
and a follower gear 36 having a follower roller 38. The diameter of
the drive roller 34 and follower roller 38 is less than the
diameter of the drive gear 34 and follower gear 36 respectively.
The drive gear 34 is connected to the power source 26. The drive
roller 34 is mounted on a spindle extending from the drive gear 34.
In one (1) embodiment, the drive gear 34 and follower gear 36 are
essentially identical. In one (1) embodiment, the driver roller and
the follower roller 38 are essentially identical. The rollers 34
and 38 have grooves (not shown) around the perimeter of the roller
to accommodate the wire 100 and to hold the wire 100 in the correct
position. The follower gear 36 and follower roller 38 are mounted
on a bail 40 which can be pivoted into an open, feed position away
from the drive gear 34. A handle 42 holds the bail 40 in the
closed, operating position. Pivoting the handle 42 unlocks the bail
40 and allows the bail 40 with the follower gear 36 and follower
roller 38 to be pivoted to the open, load position (FIG. 4). In the
open, load position, the wire 100 can be easily fed from the inlet
24A to the outlet 24B above the drive gear 34 adjacent the drive
roller 34 or in a groove in the drive roller 34. After the wire 100
is fed through the wire feeder 24, the bail 40 is moved to the
operating or closed position so that the teeth of the drive gear 34
engage the teeth of the follower gear 36. In one (1) embodiment,
the handle 42 is adjustable so that the bail 40 can be adjusted
with regard to the distance between the drive roller 34 and the
follower roller 38 to allow for wires of various diameters. In use,
when the power source 26 is activated, the drive gear 34 and drive
roller 34 are rotated in a first direction which rotates the
follower gear 36 and follower roller 38 in the opposite direction.
The oppositely turning rollers 34 and 38 contact the wire 100 and
move the wire 100 from the inlet 24A to the outlet 24B. In one (1)
embodiment, the power source 26 for the wire feeder 24 is a
pneumatic motor. In another embodiment, the power source 26 for the
wire feeder 24 is an electric motor. In the embodiment where the
power source 26 is pneumatic, after the wire 100 is fed through the
feed device 24 and the bail 40 is moved to the closed, operating
position, the air pressure on the regulator valve of the power
source 26 is set at 0 psi. Next, the valve between the power source
26 and the wire feeder 24 is slowly opened. As the air pressure to
the wire feeder 24 is increased, the wire feeder 24 starts to push
the wire 100. The amount of air pressure to pull the wire 100 from
the wire coil 102 or 104 and push the wire 100 to the welding site
will vary depending on the diameter of the wire 100, the source or
manufacturer of the wire coil 102 or 104, the type of conduit used
for the guide conduits 28 and 30, the distance between the wire
coils 102 and 104 and the wire feeder 24, the distance between the
wire feeder 24 and the welding site and the amount of curves or the
straightness of the guide conduits 28 and 30. In one (1)
embodiment, the amount of air pressure is only enough as necessary
to pull and push the wire 100. When set correctly, the wire feeder
24 stalls when the wire 100 is grasped or stopped and resumes
movement of the wire 100 when the pressure on the wire 100 is
released. In one (1) embodiment, the power source 26 for the wire
feeder 24 provides eleven (11) inch pounds of torque at 60 psi. In
another embodiment, the power source 26 provides thirty (30) inch
pounds of torque at 60 psi. The size and amount of power provided
by the power source 26 for the wire feeder 24 is dependent upon the
size or diameter of the wire 100.
[0024] The guide conduits 28 and 30 of the wire guide system guide
the wire 100 from the drums 18 and 20 to the inlet 24A of the wire
feeder 24 and from the outlet 24B of the wire feeder 24 to the
welding site (FIG. 1). In one (1) embodiment, the guide conduits 28
and 30 include a first guide conduit 28 and a second guide conduit
30. The first and second guide conduits 28 and 30 may be
constructed of several individual pieces connected together. The
first guide conduit 28 extends from the slot 23 in the top 19 of
the drum 18 or 20 to the lower guide or inlet 24A of the wire
feeder 24. In one (1) embodiment, the first guide conduit 28 is
connected to the wire transfer arm 22 which enables the first guide
conduit 28 to be moved from the slot 23 in the top 19 of the first
drum 18 to the slot 23 in the top 19 of the second drum 20 when the
first wire coil 102 is finished or depleted and the second wire
coil 104 is started. In one (1) embodiment, the first guide conduit
28 is connected to the second end 22B of the wire transfer arm 22.
The connection of the first guide conduit 28 to the second end 22B
of the wire transfer arm 22 moves the first guide conduit 28 away
from the center post 21 and allows the wire 100 to be dispensed
from essentially a center of the drum 18 or 20. In one (1)
embodiment, the first end of the first guide conduit 28 is
positioned to extend slightly into the first end 23A of the slot 23
adjacent the center of the drum 18 or 20. Connecting the first
guide conduit 28 to the second end 22B of the wire transfer arm 22
also offsets the first guide conduit 28 from the point where the
first guide conduit 28 is connected to the wire feeder 24.
Offsetting the first guide conduit 28 at the point where the wire
100 exits the top 19 from the wire feeder 24 and center post 21
provides a camming effect as the wire transfer arm 22 moves between
the drums 18 and 20. The camming effect of the offset first guide
conduit 28 helps to hold the wire transfer arm 22 in position over
each of the drums 18 and 20. In one (1) embodiment, the first guide
conduit 28 also includes a spring which allows the first guide
conduit 28 to be flexible. The spring also helps to keep the wire
transfer arm 22 in position over the drums 18 and 20. In one (1)
embodiment, the first guide conduit 28 is insulated to prevent
accidental electrification of the wire transfer arm 22. The second
guide conduit 30 extends from the upper guide or outlet 24B of the
wire feeder 24 to the feed rollers (not shown) adjacent the welding
site. In one (1) embodiment, the second guide conduit 30 extends a
distance between about 10 feet (3048 mm) and 100 feet (30480 mm)
from the wire feeder 24 to the rollers adjacent the welding site.
In one (1) embodiment, the second guide conduit 30 has bends and
curves. It is understood that the guide conduits 28 and 30 act to
guide and protect the wire 100 as it moves from the drums 18 and 20
to the welding site. However, it is understood that other means of
guiding the wire 100 between the drums 18 and 20 and the welding
site may be used.
[0025] In a second embodiment of the wire dispensing system 210,
the wire feeder 224 is positioned directly on the top 219 of the
drum 218 and services a single wire coil 102 (FIGS. 6 and 7). In
this embodiment, the frame 12 is not used. In addition, in this
embodiment, the system 210 must be deactivated before the wire coil
102 is replaced. In this embodiment, the top 219 of the drum 218
has a cone shape with a rounded apex. An opening 223 is provided in
the apex of the top 219 through which the wire 100 exits the drum
218. The opening 223 in the top 219 has an inlet probe 227. The
inlet 224A of the wire feeder 224 is mounted on the inlet probe 227
which secures the wire feeder 224 on the top 219 of the drum 218.
An inlet support disk 227 can also be provided on the top 219
around the opening 223 to help support the wire feeder 224 on the
top 219.
[0026] To use the wire dispensing system 10, the starting or first
end 102A of the first wire coil 102 is manually fed into the first
guide conduit 28 adjacent the slot 23 of the first drum 18. It is
understood that the wire coils 102 or 104 are essentially identical
and either wire coil 102 or 104 can be selected as the beginning or
first wire coil 102. The wire 100 is moved through the first guide
conduit 28 to the wire feeder 24. The wire 100 is loaded into the
wire feeder 24 from the inlet 24A to the outlet 24B. The bail 40 of
the wire feeder 24 is then moved to the closed, operating position.
The wire feeder 24 is then activated to push the wire 100 through
the second guide conduit 30 to the welding site. The finish or
second end 102B of the first wire coil 102 is welded to the start
or first end 104A of the second wire coil 104 so that the flow of
wire 100 through the system 10 is continuous. In one (1)
embodiment, the frame 12 includes a docking station (not shown)
which allows for welding the ends 102B and 104A of the first and
second wire coils 102 and 104 together. In one (1) embodiment, the
frame 12 includes a bridge which provides support for the ends 102B
and 104A to extend between the drums 18 and 20. When the first wire
coil 102 is finished or depleted, the wire 100 from the second wire
coil 104 is automatically fed into the wire dispensing system 10.
In one (1) embodiment, as the first wire coil 102 is depleted and
the wire 100 is dispensed from the second end 102B of the first
wire coil 102 to the beginning or first end 104A of the second wire
coil 104, the wire transfer arm 22 automatically moves from over
the first drum 18 having the first wire coil 102 to over the second
drum 20 having the second wire coil 104. The pull of the wire 100
in the direction of the second drum 20 overcomes the camming force
tending to hold the wire transfer arm 22 in position over the first
drum 18. As the wire transfer arm 22 moves, the wire 100 is moved
in an arc or at an angle along the slots 23 in the tops 19 of the
adjacent drums 18 and 20. As the wire 100 is drawn from the second
wire coil 104, a new wire coil (not show) is moved into the first
drum 18 and the starting end of the new wire coil is welded onto
the finishing end or second end of the second wire coil 104. In an
alternate embodiment, the drum 18 is removed and a new drum having
the new wire coil is positioned in the frame 12 adjacent the drum
20 which is currently dispensing the wire 100.
[0027] After the wire 100 exits the drum 18 or 20, the wire 100 is
moved to the inlet 24A of the wire feeder 24. Once the wire 100 is
initially fed into the wire feeder 24, the wire feeder 24 pulls the
wire 100 from the first wire coil 102 and pushes the wire 100
through the outlet 24B of the wire feeder 24 into the second guide
conduit 30 toward the welding site. As the wire 100 is pulled from
the first wire coil 102, the wire 100 moves along the curved inner
surface of the top 19 to the slot 23 which reduces friction or drag
on the wire 100 and in the system 10. As the wire 100 is pushed
through the second guide conduit 30, the wire 100 is pushed toward
the outside of any curve in the second guide conduit 30 which
reduces friction or drag on the wire 100 and in the system 10. The
amount of force on the wire 100 acting to push the wire 100 toward
the welding site and between the rollers adjacent the welding site
is selected so that there is very little drag coefficient on the
rollers and no effort on the rollers. The amount of force pushing
the wire 100 is selected so that there is little or no slippage of
the wire 100 between the rollers. Eliminating slippage between the
rollers enables constant flow of the wire 100 to the welding site.
The use of the wire feeder 24 to pull the wire 100 from the wire
coil 102 or 104 and push the wire 100 to the rollers enables the
rollers to be used to move the wire 100 only a short distance from
the rollers to the welding site. In one (1) embodiment, the wire
100 is moved at a rate of between about 50 to 1200 inches per
minute. In one (1) embodiment, the amount of push force applied by
the wire feeder 24 on the wire 100 is such that, if rollers
adjacent the welding site stall or stop, the wire feeder 24 stalls,
movement of the wire 100 stops and the wire 100 is pushed back
toward the wire feeder 24 with a constant load. If the rollers
stall or stop moving, the wire feeder 24 keeps a constant load on
the wire 100 so that when the rollers begin to move, the wire 100
is moved at a constant and steady rate of flow to the welding
site.
[0028] It is intended that the foregoing description be only
illustrative of the present invention and that the present
invention be limited only by the hereinafter appended claims.
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