U.S. patent application number 13/216189 was filed with the patent office on 2011-12-15 for tig welding system and method.
This patent application is currently assigned to ILLINOIS TOOL WORKS INC.. Invention is credited to Richard Mark Achtner, Bruce Patrick Albrecht, LeRoy H. Lauer, JR..
Application Number | 20110303647 13/216189 |
Document ID | / |
Family ID | 39705747 |
Filed Date | 2011-12-15 |
United States Patent
Application |
20110303647 |
Kind Code |
A1 |
Achtner; Richard Mark ; et
al. |
December 15, 2011 |
TIG WELDING SYSTEM AND METHOD
Abstract
The invention provides a welding arrangement designed to respond
to the need of an improved welding system that aids in supplying
filler material to a weld location. Provided is a welding system
including a welding gun and a welding wire feed directly coupled to
the welding gun. The welding gun includes a filler material
housing, a filler material positioning extension, and a manual
advancement device configured to advance a filler material through
the welding wire feed. Further provided is a method of operating a
welding gun. The method includes passing a current between an
electrode and a work piece at a weld location, and advancing a
filler material toward the weld location via a channel of a
positioning extension in response to engagement of a manual
advancement device.
Inventors: |
Achtner; Richard Mark;
(Appleton, WI) ; Albrecht; Bruce Patrick;
(Grayslake, IL) ; Lauer, JR.; LeRoy H.;
(Hortonville, WI) |
Assignee: |
ILLINOIS TOOL WORKS INC.
Glenview
IL
|
Family ID: |
39705747 |
Appl. No.: |
13/216189 |
Filed: |
August 23, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11969789 |
Jan 4, 2008 |
8026456 |
|
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13216189 |
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60902315 |
Feb 20, 2007 |
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Current U.S.
Class: |
219/137.62 ;
219/137.31 |
Current CPC
Class: |
B23K 9/173 20130101;
B23K 9/167 20130101; B23K 9/296 20130101; B23K 9/133 20130101; B23K
9/295 20130101 |
Class at
Publication: |
219/137.62 ;
219/137.31 |
International
Class: |
B23K 9/28 20060101
B23K009/28 |
Claims
1. A system, comprising: a welding torch, comprising; a nozzle
comprising an electrode; and a filler material positioning
extension comprising an extension channel that terminates at an
extension end proximate the electrode, wherein the extension end is
capable of being manipulated between at least a first position and
a second position.
2. The system of claim 1, wherein the system comprises a local
welding wire feeder coupled directly to the welding torch and
configured to feed filler material to a weld location via the
filler material positioning extension.
3. The system of claim 1, wherein the filler material positioning
extension comprises a material that is positionable between at
least the first position and the second position.
4. The system of claim 1, wherein the filler material positioning
extension is deformable between at least the first position and the
second position.
5. The system of claim 1, wherein the filler material positioning
extension comprises a first section and a second section, wherein
the first section and the second section are configured to pivot
relative to one another.
6. The system of claim 1, wherein the filler material positioning
extension is rotatable about an axis of the electrode.
7. The system of claim 1, wherein the filler material positioning
extension comprises a thermal insulating component.
8. A welding gun, comprising: a torch body comprising a body axis;
a torch handle comprising a handle axis; a torch nozzle comprising
a nozzle axis; an electrode comprising an electrode axis; a wire
feeder comprising a feeder axis; and a wire positioning extension,
comprising: a guide channel comprising a guide channel axis; and an
exit channel comprising an exit channel axis, wherein the exit
channel terminates proximate the electrode, and wherein the body
axis, the handle axis, the nozzle axis, the electrode axis, the
guide channel axis, and the exit channel axis are located in a
first plane.
9. The welding gun of claim 8, wherein the feeder axis is
transverse to the first plane.
10. The welding gun of claim 8, wherein the nozzle axis and the
electrode axis are coaxial, and the guide channel axis is parallel
and offset from the nozzle axis and the electrode axis.
11. The welding gun of claim 10, wherein the exit channel axis
intersects the guide channel axis and the electrode axis.
12. The welding gun of claim 8, wherein the wire feeder comprises a
motorized wire feeder.
13. The welding gun of claim 8, wherein the wire feeder comprises a
manual wire feeder having a manual advancement device.
14. The welding gun of claim 8, wherein the wire positioning
extension is deformable between a plurality of positions.
15. The welding gun of claim 8, wherein the wire positioning
extension comprises a first section and a second section, wherein
the first section and the second section are configured to pivot
relative to one another.
16. The welding gun of claim 8, wherein the wire positioning
extension is rotatable about the electrode axis.
17. The welding gun of claim 8, wherein the wire positioning
extension comprises a thermal insulating component.
18. A system, comprising: a welding torch, comprising; a nozzle
comprising an electrode; and a filler material positioning
extension comprising an extension channel that terminates at an
extension end at an offset distance from the electrode, wherein the
offset distance is adjustable; and a local welding wire feeder
coupled directly to the welding torch, wherein the local welding
wire feeder is configured to feed filler material to a weld
location via the filler material positioning extension.
19. The system of claim 18, wherein the filler material positioning
extension is deformable to adjust the offset distance.
20. The system of claim 18, wherein the filler material positioning
extension comprises at least one axis of rotation to adjust the
offset distance.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/969,789, entitled "TIG Welding System and Method,"
filed Jan. 4, 2008, which is herein incorporated by reference in
its entirety, and which claims priority to U.S. Provisional Patent
Application No. 60/902,315, entitled "TIG Welding System and
Method", filed on Feb. 20, 2007, which is herein incorporated by
reference in its entirety.
BACKGROUND
[0002] The invention relates generally to the field of welding
systems, and particularly to welding systems that supply a filler
material to weld locations during welding.
[0003] Welding systems generally include an electrode configured to
pass an arc between a torch and a work piece, thereby heating the
work piece to create a weld. In many systems, such as metal inert
gas (MIG) welding and stick welding systems, the electrode is a
consumable wire that melts into the weld to provide a filler
material into the weld. In other words, a single wire serves both
as an electrode and as the filler material. In contrast, tungsten
inert gas (TIG) welding systems employ a non-consumable tungsten
electrode that is independent from the filler material. In other
words, the TIG welding process does not melt the tungsten electrode
into the weld forming on the work piece. Instead, a user generally
holds the TIG torch with the tungsten electrode in a right hand,
while the user simultaneously and independently holds the filler
material in a left hand. Unfortunately, this two-handed technique
for TIG welding does not leave any hands free for controlling the
welding current, wire feed rate, and so forth. Thus, a user may
need to stop the welding process (e.g., set down the TIG torch or
the tungsten electrode) in order to adjust various controls. As a
result, the welding process may create a less than desirable weld
due to the delays in adjustments, breaks in the weld continuity,
and so forth.
BRIEF DESCRIPTION
[0004] In certain embodiments, a welding torch includes both a
welding electrode and a filler material, which are independently
supported and guided toward a weld on a work piece. For example,
one embodiment includes a welding system having a welding gun and a
welding wire feed directly coupled to the welding gun. The welding
gun includes a filler material housing, a filler material
positioning extension, and a manual advancement device configured
to advance a filler material through the welding wire feed.
[0005] In accordance with another embodiment, a system includes a
welding torch. The welding torch includes a nozzle having an
electrode and a filler material positioning extension. The filler
material positioning extension has an extension channel that
terminates at an extension end proximate the electrode. The
extension end is capable of being manipulated between at least a
first position and a second position.
[0006] In accordance with another embodiment, a welding gun
includes a torch body having a body axis, a torch handle having a
handle axis, a torch nozzle having a nozzle axis, an electrode
having an electrode axis, a wire feeder having a feeder axis, and a
wire positioning extension. The wire positioning extension includes
a guide channel having a guide channel axis and an exit channel
having an exit channel axis. The exit channel terminates proximate
the electrode. The body axis, the handle axis, the nozzle axis, the
electrode axis, the guide channel axis, and the exit channel axis
are located in a first plane.
[0007] Another embodiment, includes a wire feeder retrofit kit. The
wire feeder retrofit kit includes a wire feeder that includes a
filler material housing, a filler material positioning extension,
and a manual advancement device configured to advance the filler
material. Further, the wire feeder is configured to be coupled to a
welding gun, and the wire feeder is configured to guide the filler
material toward an electrode of the welding gun.
[0008] Another embodiment includes a method of operating a welding
gun. The method includes passing a current between an electrode and
a work piece at a weld location, and advancing a filler material
toward the weld location via a channel of a positioning extension
in response to engagement of a manual advancement device.
DRAWINGS
[0009] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0010] FIG. 1 is an illustration of an exemplary welding system in
accordance with embodiments of the present invention;
[0011] FIG. 2 is an illustration of an exemplary embodiment of a
torch of the welding system of FIG. 1;
[0012] FIG. 3 is an illustration of an exemplary embodiment of a
spool of the torch of FIG. 2;
[0013] FIG. 4 is an illustration of an alternate embodiment of a
spool of the torch of FIG. 2;
[0014] FIG. 5 is an illustration of an exemplary embodiment of a
spool cover;
[0015] FIGS. 6, 7, and 8 are illustrations of alternate embodiments
of the torch of the welding system of FIG. 1;
[0016] FIG. 9 is a schematic of an exemplary embodiment of a remote
mechanism of the torch of the welding system of FIG. 1;
[0017] FIG. 10 is a schematic of an alternate embodiment of a
remote mechanism of the torch of the welding system of FIGS. 1;
and
[0018] FIGS. 11 and 12 are illustrations of further alternate
embodiments of the torch of the welding system of FIG. 1.
DETAILED DESCRIPTION
[0019] Referring now to FIG. 1, a welding system 10 in accordance
with one embodiment of the present technique is illustrated with
both an electrode 44 and a filler material 62 in an independent
arrangement. As discussed in greater detail below, the filler
material 62 may be thermally shielded and/or disposed away from the
electrode 44, which generates a significant amount of heat during a
welding process. In other words, the electrode 44 and the filler
material 62 may be kept apart from one another to reduce the
possibility of the filler material 62 corrupting the electrode 44,
or the electrode 44 prematurely melting the filler material 62, or
both. In the illustrated embodiment, the welding system 10 includes
a tungsten inert gas (TIG) welding system, and thus the electrode
44 is a non-consumable tungsten electrode. However, other
embodiments may include other types of consumable or non-consumable
electrodes. Further, as discussed in greater detail below, the
unified support of both the electrode 44 and the independent filler
material 62 on the torch 18 enables a one-handed operation of the
torch 18, such that a user can use a free hand to adjust welding
controls, steady his/her position, grab the work piece, and so
forth. Moreover, the unified support of both the electrode 44 and
the filler material 62 on the torch 18 improves the spacing,
direction, and general position of the filler material 62 relative
to the electrode 44, rather than requiring independent positioning
of the electrode 44 and the filler material 62 in different hands
of the user. In other words, the spacing, angle, and general
orientation of the filler material 62 relative to the electrode 44
remain consistent throughout the welding process. In some
embodiments, the orientation between the filler material 62 and the
electrode 44 may be changed by a guide structure. Furthermore, in
some embodiments, the feed rate of the filler material 62 and other
welding parameters may be controlled directly on the torch 18
rather than the power source 12.
[0020] As depicted, the TIG welding system 10 includes a power
source 12, a shielding gas source 14, a cooling system 16, and a
torch 18. In the illustrated embodiment, the power source 12
provides power to the welding torch 18 via a supply conduit 20. The
power source 12 may supply a direct current (DC) or alternating
current (AC) to the torch 18 depending on the desired application.
For example, an AC current may be suited for welding aluminum or
magnesium, and a DC current may be suited for welding stainless
steels, nickel or titanium. In addition to matching the current to
the material selection, the output of the power source 12 may be
varied to obtain desired weld characteristics. For example, a low
AC frequency (e.g., 60 Hz) current may generate a wide arc with
shallow penetration of a work piece 22, while a high AC frequency
(e.g., 200 Hz) current may generate a focused arc with deeper
penetration into the work piece 22.
[0021] In addition to the frequency of the current, the power
source 12 may vary the amperage of the current output to the torch
18. The setting for the amperage output by the power source 12 may
be adjusted by a setting a knob or button on the power source 12,
or may be set by a remote control 24. For example, a welding system
10 may include a foot pedal remote control 24 that allows the
operator to make current adjustments during welding by either
holding down the foot pedal or feathering the foot pedal remote
control 24 to vary the amperage. The remote control 24 may also
include a finger tip control, audible command, or other form of
input to signal the power source 12 to output a corresponding
current.
[0022] In addition, the torch 18 may be supplied with a shielding
gas from a supply 14. In general, the shielding gas may be supplied
to the torch 18 and expelled from the torch at the location of the
weld. The shielding gas may be expelled immediately prior to
striking the welding arc, throughout welding, and/or until shortly
after the welding arc is extinguished. The shielding gas protects
the welding area from atmospheric gases such as nitrogen and
oxygen, which can cause fusion defects, porosity, and weld metal
embrittlement. The shielding gas may also transfer heat from the
welding electrode to the metal and may help to start and maintain a
stable arc.
[0023] As depicted in FIG. 1, the shielding gas may be provided in
a container and delivered to the torch 18 via a regulator 26, a
conduit 28, a gas valve 30, and the supply conduit 20. The
regulator 26 may allow an operator to limit the pressure of the gas
delivered to the gas valve 30 to obtain a desired flow rate.
Further, the gas valve 30 may provide for stopping and starting the
flow of the shielding gas to the torch 18 in coordination with
other welding operations.
[0024] The TIG welding system 10 may be provided with a cooling
system 16 to reduce heat build-up. The cooling system may take
various forms including gas cooled and liquid cooled systems. The
cooling system 16 may provide for circulation of the coolant via
coolant supply conduits 32 and 34 and coolant return conduit 36.
The cooling system may be powered from the power supply 12 via a
coolant system power cord 38.
[0025] In general, the welding system 10 may provide for current
flow via a work piece 22 to the power source 12. For example, as
depicted in FIG. 1, the welding system 10 may include a cable 40
that is secured to the work piece 22 via a work clamp 42. In this
configuration, the current provided by the power source 12 flows
through the supply conduit to the torch 18, flows across an arc
from an electrode 44 to the work piece 22, and returns to the power
source 12 via the work clamp 42 and the cable 40.
[0026] As illustrated in FIGS. 1 and 2, one embodiment of the TIG
welding torch 18 includes a handle 46 that is attached to a torch
body 48. The handle 46 includes a handle axis 47 (see FIG. 2)
running along its length, and may include a hollow interior to
facilitate routing power, shielding gas, and coolant to the welding
torch 18. The torch body 48 may also include a torch neck 50 and a
torch head 52, as illustrated. The torch body 48 may provide a
central-rigid support to mount hardware on the torch 18. For
example, the torch neck 50 provides for securing the handle 46 to
other components, and enables an operator to hold and manipulate
the welding torch 18 and its components via the handle 46. The
torch body 48 may include a body axis 53 (see FIG. 2) running along
its length, through the torch head 52 and through the torch neck
50.
[0027] Other components of the welding torch 18 that are coupled to
the torch body 48 may include an insulator 54, a nozzle 56, a
collet 58, the electrode 44, and a back cap 60. The insulator 54
may be positioned on the interior of the torch body 48 to block
heat produced by the welding current from passing into the torch
body 48 and/or the handle 46. The nozzle 56 may be attached to the
insulator 54 or the torch head 52 of the torch body 48. The nozzle
56 may include a hollow tubular shaped piece that encloses the
collet 58 and the electrode 44, and provides a path for the
shielding gas to pass between an interior surface of the nozzle 56
and the collet 58. As illustrated, the nozzle 56 may include a
nozzle axis 59 (see FIG. 2) that runs along its length. In one
embodiment, the nozzle axis 59 is coaxial with the body axis 53.
Further, the electrode 44 may include an electrode axis 61 (see
FIG. 2) that runs along its length and that is coaxial with the
nozzle axis 59 and/or the body axis 53.
[0028] The illustrated welding system 10 also includes the filler
material 62. As discussed above, the torch 18 supports the filler
material 62 independently from the electrode 44, such that a user
does not need to hold the filler material 62 separate from the
torch 18. The illustrated torch 18 also facilitates advancing
and/or supplying the filler material 62 to the weld location and
weld pool as needed. For example, a source of the filler material
62 may be located proximate (e.g. local) to the welding torch 18,
such that it can be fed to the weld location in a consistent manner
relative to the electrode 44. One embodiment of the torch 18 may
include a spool containing a coil of filler material 62 attached to
the torch 18. For example, as depicted in FIG. 2, the welding torch
18 may include a spool assembly 64 coupled to the end of the torch
handle 46 opposite the torch body 48. The spool assembly 64 may
include a spool 66 that is configured to house and support the
filler material 62. The filler material 62 may include a wire that
is wound about the spool 66, for example. In one embodiment, the
spool 66 may be rotated to discharge the filler material 62 that is
wound about the spool 66. For example, as depicted in FIG. 2, the
spool 66 may be rotated counter-clockwise about a spool axis 67 to
un-roll the filler material 62 such that the filler material 62 is
guided along the torch 18 and to the weld location. As depicted in
the illustrated embodiment, the spool axis 67 may run transverse to
the handle axis 47, and or the body, the nozzle, and the electrode
axes 53, 59, and 61.
[0029] In one embodiment, the spool assembly 64 may include a
generally round spool 66 that rotates about the spool axis 67. For
example, as depicted in FIG. 3, the spool 66 may include two rims
68 at the ends of a cylindrical center 70 with filler material 62
wound about the cylindrical center 70. In one embodiment, the spool
66 may be approximately 2 inch to 3 inches in total diameter.
Further, the spool 66 may include a spindle hole 72 that extends
through the spool axis 67 to facilitate mounting the spool 66 to a
spindle, for example. Thus, the filler material 62 may be stored on
the spool 66 and discharged by rotating the spool 66 about the
spindle. The spool 66 may take a variety of forms to accommodate
storing and dispensing the filler material 62. For example, the
spool 66 may be increased or decreased in dimensions to accommodate
more of less filler material 62, or may take a variety of shapes.
Further, the body of the spool 66 may be formed from a wireframe
body or a solid body configured to support the filler material 62
and interface with other components of the spool assembly 64 and
the torch 18. Various spool geometries may be used to minimize wire
cast and helix.
[0030] In another embodiment, the spool 66 may include an enclosed
cylinder 74. For example, as depicted in FIG. 4, the enclosed
cylinder 74 may allow filler material 62 to be coiled about the
interior of the spool 66 and discharged through an exit hole 76.
Thus, similar to the previous embodiment, the filler material 62
may be stored in the spool 66 and discharged by drawing the filler
material 62 from the spool 66. Further, the spool 66 may include a
spindle hole 72 coaxial with the spool axis 67 to facilitate
mounting the spool 66 to a spindle.
[0031] In addition, the spool 66 may also provide for
interchangeable spool cartridges. For example, in one embodiment,
the spool assembly 64 may include a common coupling device, such as
a spindle hole 72. Thus, multiple spools 66 may be coupled to the
spool assembly 64. For example, an operator may exchange an empty
spool 66 for a pre-loaded spool 66 by simply removing the empty
spool and replacing it with a spool 66 that is pre-loaded with
filler material 62. The spool 66 may include a variety of shapes
and sizes that are capable of providing a variety of filler
material configurations. Thus, the spool 66 may provide for filler
material 62 of differing amounts, types, and sizes to be stored on
and dispensed from the spool 66.
[0032] The spool assembly 64 may also include a spool cover 78. For
example, as depicted in FIG. 5, the spool cover 78 may include a
body that surrounds the spool 66 and the filler material 62
disposed on the spool 66. The spool cover 78 may slide off the
spool 66 and be secured by an interference fit, for example. In one
embodiment, the spool cover 78 may be configured to provide
protection of the filler material 62 from the surrounding welding
environment and during storage. For example, the spool cover 78 may
include a rigid material configured prevent physical impacts from
severing the filler material 62. In an additional embodiment, the
spool cover 78 may include insulating properties to protect the
filler material 62 from the temperatures near the weld location to
prevent the filler material 62 from melting on the spool 66 before
it is advanced to the weld location. In addition, the spool cover
78 may be coupled to the torch 18 and include keying features to
assist the operator in more easily aligning the spool 66 when it is
assembled. Further, the spool cover 78 may include an indicator to
display to the operator the type or amount of filler material 62
remaining on the spool 66.
[0033] The spool assembly 64 and/or the torch 18 may also include a
route to manipulate and shield the filler material 62 as it is
discharged from the spool 66. For example, to properly align the
filler material 62 with the weld location and the weld pool, the
spool assembly 64 and/or the torch 18 may include a positioning
device 80 (see FIG. 2). For example, as depicted in FIG. 2, the
positioning device 80 may include a channel 82 that passes through
and/or around the handle 46 of the torch 18 and through a
positioning extension 84, and that facilitates delivery of the
filler material 62 to the weld location. In other words, the
positioning device 80 acts as a guide to direct the filler material
62 in the proper direction, spacing, rotation and general
orientation relative to the electrode 44, the weld location, joint
and direction of travel.
[0034] The positioning device 80 may take a variety of forms
suitable for aligning the filler material 62 with the weld
location. For example, in one embodiment, the channel 82 of the
positioning device 80 may run internal to the handle 46, as
depicted by FIG. 2. In another embodiment, the channel 82 and the
positioning extension 84 may include a single tube external to the
handle 46 that runs the length of the handle 46 and spans the
distance between the spool 66 and the weld location.
[0035] In the illustrated embodiment, the positioning extension 84
includes a guide axis 85A and an exit axis 85B. The guide axis 85A
runs along a length of a portion of the channel 82 that extends
from the torch handle 46 to a bend in the positioning extension 84.
The exit axis 85B runs along a length of the channel 82 in the
positioning extension 84 from the bend in the positioning extension
84 to an end of the positioning extension 84 proximate the
electrode 44. In the illustrated embodiment, the guide axis 85A is
parallel and offset from the body axis 53, the nozzle axis 59, and
the electrode axis 61. The exit axis 85B intersects the guide axis
85A and the electrode axis 61. Further, the guide axis 85A, the
exit axis 85B, the handle axis 47, body axis 53, the nozzle axis
59, and the electrode axis 44 are all located in a single
plane.
[0036] The end of the positioning device 80 proximate the weld
location may include various forms to control the direction,
spacing, rotation and general orientation of the filler material 62
relative to the weld location, joint and direction of travel. In
one embodiment, the tip of the positioning device 80 may be coupled
to the nozzle 56. For example, as depicted in FIGS. 2, 6, and 7,
the positioning extension 84 may be coupled to the body of the
nozzle 56. In one embodiment, the nozzle 56 may be formed as a
single piece that includes a channel defining the positioning
extension 84. In another embodiment, the positioning extension 84
may be welded, or similarly attached, to the nozzle 56. Thus, as
the nozzle 56 is rotated about the electrode axis 61, the position
of the filler material 62 may be modified.
[0037] With a path for the filler material 62 provided, a mechanism
may be used to advance the filler material 62 from the source of
filler material (e.g. the spool 66) to the weld location. In one
embodiment, the spool assembly 64 may include a drive to pull or
push the filler material 62 from the spool 66 through the
positioning device 80. For example, as depicted in FIG. 2, the
spool assembly 64 may include a motor 86 configured to rotate the
spool 66 counter-clockwise and advance the filler material 62 from
the spool 66. The motor 86 may be mechanically coupled to the spool
66 and rotate the spool 66 when power is supplied to the motor 86.
Thus, the filler material 62 may be pushed from the spool 66 to the
weld location via the positioning device 80. The spool assembly 64
and motor 86 may have a variety of configurations. For example, in
one embodiment, the motor 86 may transfer torque to the spool 66
via mechanical coupling to a spindle along the axis of the spool
66.
[0038] Although pushing the filler material 62 may be appropriate
in some embodiments, pulling the filler material 62 from the spool
66 may be advantageous to prevent bucking of the filler material 62
as it advances to the weld location. Thus, in one embodiment, the
spool assembly 64 may be configured to pull the filler material 62
from the spool 66. For example, as depicted in FIG. 6, the spool
assembly 64 may include the motor 86 configured to draw the filler
material 62 from the spool 66 and advance the filler material 62 to
the weld location via the positioning device 80. An embodiment may
include the motor 86 rotating at least one of two puller-wheels 88
to draw the material from the spool 66. For example, in one
embodiment, the gap between the puller wheels 88 may be
sufficiently small to maintain a pressure on the filler material 62
and enable the torque transferred from the motor 86 to the puller
wheel(s) 88 to advance the filler material 62 to the weld location
via the positioning device 80. The motor 86 and puller wheels 88
may be provided in a variety of configurations. For example, in one
embodiment, the motor 86 and puller wheels 88 may be located at the
end of the positioning device 80 near the weld location and,
thereby, pull the filler material 62 through the positioning device
80.
[0039] Reducing the travel distance of the filler material 62 also
may reduce the force needed to move the filler material 62 and may
reduce the complexity of the routing mechanism. In one embodiment,
the filler material 62 may be attached to the torch 18 at or near
the torch body 48. For example, as depicted in FIG. 7, the spool
assembly 64 may be coupled to the torch neck 50. Thus, the filler
material 62 may be discharged from the spool 66 into the
positioning device 80 proximate to the weld location. The spool
assembly 64 may be coupled to the torch 18 in a multitude of
configurations. For example, the spool assembly 64 may be coupled
to the handle 46, the torch neck 50, the torch head 52, or a
combination thereof. The spool assembly 64 may incorporate a
pushing motor/device coupled to the spool 66, or a pulling
motor/device that is positioned between the spool 66 and the weld
location, as discussed previously.
[0040] Another embodiment may position the spool assembly 64 above
the torch body 48. For example, as depicted in FIG. 8, the torch 18
may include an in-line design that couples the spool assembly 64
generally along the electrode axis 61 and/or the body axis 53. In
such an embodiment, the positioning device 80 may run the length of
the torch 18, and thus reduce the bending of the filler material 62
as it is routed from the spool 66 to the weld location. The reduced
bending of the filler material 62 may enable use of a thicker gauge
wire of filler material 62. The spool assembly 64 and a housing 90
may be configured in any suitable arrangement to provide the filler
material 62 to the weld location. For example, the spool 66 may be
coupled to a motor 86 to push the filler material through the
positioning device 80. Further, the spool assembly may include a
motor separate from the spool 66 that is configured to pull the
filler material 62 from the spool 66. For example, a motor may be
located in the housing 96 to draw the filler material 62 from the
spool 66. Similar to the previously discussed embodiments, the
guide axis 85A is parallel and offset from the body axis 53, the
nozzle axis 59, and the electrode axis 61. The exit axis 85B
intersects the guide axis 85A and the electrode axis 61. Further,
the guide axis 85A, the exit axis 85B, the handle axis 47, body
axis 53, the nozzle axis 59, and the electrode axis 61 are all
located in a single plane.
[0041] The torch 18 also may incorporate a remote 92 to signal the
motor 86 to operate to advance or retract the filler material 62.
In one embodiment, the remote 92 may include a trigger located on
the torch 18. For example, as depicted in FIG. 9, the trigger of
the remote 92 may enable a user to depress the trigger to compete
the circuit between the power source 12 and the motor 86. In
another embodiment, the remote 92 may include a foot pedal. For
example, as depicted by FIG. 10, the foot pedal of the remote 92
may be depressed to complete the circuit between the power source
12 and the motor 86. The signal to operate the motor 86 may be
provided by any suitable source. For example, the motor 86 may be
operated by a circuit configured to respond to voice commands of
the operator. Further, the power supply used to power the motor 86
may include a battery or other power source independent from the
system power source 12.
[0042] Another embodiment may include a control algorithm to
advance the filler material 62 in response to the signal to an
operator's signal to advance the filler material. For example in
one embodiment, although the filler material 62 may generally be
advanced forward, the filler material 62 may be advanced into the
molten puddle and then retracted to provide weld that resembles a
series of puddles. Retraction also eliminates ball formation on the
end of the wire. Further, the control algorithm may be carried out
in accordance with a signal from the power supply or a control
located on or proximate to the torch 18.
[0043] Although a motor 86 may provide for automated discharge of
the filler material 62, other welding systems 10 may be more suited
for manual advancement of the filler material 62. These may include
high precision welding systems 10 in which an operator advances the
filler material 62 at a slower feed rate. In one embodiment, a feed
mechanism for the filler material 62 may include a finger operated
control. For example, as depicted in FIG. 11, the torch 18 includes
a feed assembly 94 having a housing 96, a manual advancement
mechanism 97, and the positioning extension 84. In operation, the
filler material 62 may be inserted and/or stored in the housing 96,
and advanced to the weld location and/or the electrode 44 via the
positioning device 80 in response to the operator activating the
manual advancement mechanism 97.
[0044] In one embodiment, the housing 96 may be coupled to the
handle 46 and/or torch body 48. For example, the housing 96 may
include a rigid structure that is coupled to and runs along the
length of the handle 46 (e.g., parallel to the handle axis 47).
Further, the housing 96 may include a central channel 98 that runs
along its length. The central channel 98 may be parallel to the
handle axis 47, as illustrated. Further, the central channel 98 may
include a cylindrical hole or tube that enables a generally round
tube or wire of the filler material 62 to be inserted into the
channel 82 via an inlet 99 of the housing 96 proximate an end of
the handle 46 that is opposite the torch body 48. Further, the
central channel 98 may be coaxial with and/or include at least
portion of the channel 82 of the positioning extension 84. In other
words, the central channel 98 and the channel 82 of the positioning
device 80 may define a continuous channel. Accordingly, in one
embodiment, the operator may insert the filler material 62 into the
central channel 98 of the housing 96 via the inlet 99, and engage
the manual advancement mechanism 97 to advance the filler material
62 through central channel 98 and the channel 82 of the positioning
device 80. In turn, the positioning extension 84 ejects the filler
material 62 proximate the electrode 44. Similarly, the operator may
engage the manually advancement mechanism 97 in the reverse
direction to retract the filler material 62.
[0045] The manual advancement mechanism 97 may include any variety
of devices that facilitate manual advancement of the filler
material 62. For example, in the illustrated embodiment, the manual
advancement mechanism 97 includes a dial 100 that can be rotated to
advance the filler material 62. For example, in one embodiment, a
circumference of the dial 100 directly contacts the filler material
62. Accordingly, rotating the dial 100 exerts a force on the filler
material 62 that causes the filler material 62 to advance or
retract. In another embodiment, the manual advancement mechanism 97
may include a slide 102 in place of, or in addition to, the dial
100. The slide 102 may be may be coupled to or abut the filler
material 62, such that moving the slide 102 exerts a force on the
filler material 62 that causes the filler material 62 to advance or
retract. For example, the slide 102 may be moved in a direction
parallel to the handle axis 47 and in the direction of the torch
head 52 to advance the filler material 62 and/or the slide 102 may
be moved in an opposite direction to retract the filler material
62.
[0046] Further, the manual advancement mechanism 97 may include a
device that is suited for thumb operated control and/or may be
integrated to a variety of welding devices. For example, as
depicted in FIG. 12, a goose-neck type torch 18 may include a feed
assembly 94 integral to the torch 18. As illustrated, the feed
assembly 94 includes an integrated handle 46 and housing 96, the
manual advancement mechanism 97, and the positioning device 80. In
one embodiment, the housing 96 may be directly coupled to the
handle 46, include the central channel 98 to facilitate insertion
of a filler wire 62, and provide a location for the operator to
grip the torch 18. Further, the torch 18 may include the manual
advancement mechanism 97 embedded in the housing 96, thus
facilitating manually advancing the filler material 62 through the
positioning device 80 to the weld location with the use of a single
hand.
[0047] Other embodiments may include any form of the manual
advancement mechanism 100 that facilitates an operator to manually
advance the filler material 62 through the positioning extension
84. For example, the embodiments of FIGS. 11 and 12 may incorporate
a spool that is capable of being manually advanced in a similar
fashion. Thus, a coil of wire filler material 62 may be used in
place of, or in addition to, the rod of filler material 62. In
other embodiments, the manual advancement mechanism 97 may include
other forms of knobs or buttons configured to advance the filler
material 62.
[0048] It will be appreciated by those ordinarily skilled in the
art that the embodiments described may be configured in any
suitable combination of features. For example, a motor 86 may be
configured for use on the embodiments of FIG. 11 and FIG. 12. Thus,
a motor 86 may be used to advance a straight filler material 62
(e.g., rod or wire) as opposed to a coil of filler material 62
advanced from a spool 66. Moreover, the manual advancement
mechanism 97 may act as a trigger to engage an electrical drive,
such as the motor 86.
[0049] As mentioned previously, the positioning extension 84 may be
used for alignment of the filler material 62 to the weld location.
As depicted in FIGS. 2, 6, 7, 8, 11 and 12, the positioning
extension 84 may include a tube that is rigidly coupled to the
torch 18. However, in some embodiments it may be beneficial to
enable adjustment of the positioning extension 84. In other words,
it may be beneficial for the positioning extension 84 to be
manipulated between at least a first and a second position. For
example, one embodiment may include the positioning extension 84
being configured to flexibly adjust the location and exit of the
positioning extension 84. Thus, an operator may simply adjust the
positioning extension 84 to control where and how the filler
material 62 is ejected relative to the electrode 44 and the weld
location. In one embodiment, the positioning extension 84 may be
formed from a flexible material that enables the positioning
extension 84 to be deformed such that the filler material 62 is
ejected at a different point, angle, and/or along a different axis.
In another embodiment, only a segment of the positioning extension
84 may be formed from relatively pliable material that is
deformable. In another embodiment, the positioning extension 84 may
include two sections (e.g., a first section and a second section)
that are configured to pivot relative to one another. For example,
a first portion of the positioning extension 84 along the guide
axis 85A may pivot relative to a second portion of the positioning
extension along the exit axis 85B. The two portions may be joined
by a portion of the positioning extension 84 having a reduced
cross-section, a hinge, a ball and socket, or any other suitable
pivoting device. In yet another embodiment, the positioning
extension 84 may include a corrugated or ribbed tubing that is
capable of flexing and bending to vary the orientation and/or
position of the positioning extension 84.
[0050] The torch 18 may also include additional shielding and
configurations that protect the filler material 62 from the heat
produced by the welding process. For example, in one embodiment,
the positioning extension 84 may include thermal insulation to
shield the filler material 62 from the high temperatures proximate
the electrode 44. In one embodiment, an insulating component, such
as an insert, may be disposed internal, external, or integral to
the positioning extension 84 and/or the channel 82. In another
embodiment, spool assembly 64, feed assembly 94 and/or positioning
device 80 may be formed from a refractory material capable of with
standing the elevated temperatures proximate to the molten material
of the weld pool and the arc. Components of the feed assembly 94
may be formed from any variety materials, including but not limited
to: alumina ceramic, titanium, tungsten, plastic, glass filled
plastic, ceramics, copper, stainless steel or other materials.
[0051] As described in the previous embodiments, the torch 18 may
include multiple components that provide for storage, advancement,
and alignment of the filler material 62. In an embodiment, these
components may be manufactured as part of the torch 18. However, it
may be beneficial to add the spool assembly 64, the feed assembly
94, the positioning device 80, and/or other components to the torch
18 and system 10 subsequent to manufacture (e.g., retrofitting). In
one embodiment, the spool assembly 64 and/or the feed assembly 94
may be an add-on device that is capable of being coupled to the
welding torch 18. For example, the spool assembly 64 and/or feed
assembly 94 may include a separate component that an operator can
subsequently attach to the torch body 48. The spool assembly 64,
the feed assembly 94, the positioning device 80, and/or other
components may be attached to the torch 18 in a variety of
configurations. These components may be attached to other
components on or proximate to the torch 18, including the supply
conduit 20, the coolant supply conduit 34, and/or the coolant
return conduit 36, for example.
[0052] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
* * * * *