Reciprocating wire feed welding system and method

Patent metadata

Field	Value
Publication number	US-11969836-B2
Application number	US-202016984922-A
Country	US
Kind code	B2
Filing date	Aug 4, 2020
Priority date	Dec 28, 2015
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

First claim

The invention claimed is:

1. A method, comprising:
driving rotation of a gear of a reciprocating welding wire feed system with a motor rotating in only one rotational direction;
feeding a welding wire through the reciprocating welding wire feed system in a first linear direction by driving the gear in the one rotational direction;
retracting the welding wire through the reciprocating welding wire feed system in a second linear direction opposite the first linear direction by driving the gear in the one rotational direction;
applying an electrical signal to a first expandable roll to radially expand the first expandable roll such that the first expandable roll captures the welding wire with a first drive roll to feed the welding wire in the first linear direction;
suspending application of the electrical signal to the first expandable roll to radially contract the first expandable roll such that the first expandable roll disengages from the welding wire and the first drive roll; and
applying the electrical signal to a second expandable roll to radially expand the second expandable roll such that the second expandable roll captures the welding wire with a second drive roll to retract the welding wire in the second linear direction.

2. A consumable filler metal delivery system, comprising:
a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion; and
a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system;
wherein the reciprocating wire feeding gear assembly comprises piezoelectric actuators configured to move the wire forward and backward with the net forward motion.

3. The system of claim 2 , wherein the system is configured to perform a gas metal arc welding, flux-cored arc welding, submerged arc welding, hot wire/cold wire tungsten inert gas welding, laser welding, plasma welding, cladding, brazing process, a multi-wire process, or any combination thereof.

4. The system of claim 2 , comprising a wire feeder, wherein the reciprocating wire feeding gear assembly and the motor are disposed within the wire feeder.

5. The system of claim 2 , comprising a welding torch, wherein the reciprocating wire feeding gear assembly and the motor are disposed within the welding torch.

6. The system of claim 2 , wherein operation of the reciprocating wire feeding gear assembly is synchronized with a welding current waveform of the system.

7. A reciprocating welding wire feed system, comprising:
a first drive roll configured to contact a welding wire;
a second drive roll disposed adjacent to the first drive roll on a same side of the welding wire, wherein the second drive roll is configured to contact the welding wire,
a first expandable roll disposed opposite the first drive roll relative to the welding wire; and
a second expandable roll disposed opposite the second drive roll relative to the welding wire;
wherein the first expandable roll is configured to expand radially upon application of an electrical signal to the first expandable roll, and the second expandable roll is configured to expand radially upon application of the electrical signal to the second expandable roll.

8. The system of claim 7 , wherein the first expandable roll is configured to contract radially upon suspension of the application of the electrical signal, and the second expandable roll is configured to contract radially upon suspension of the application of the electrical signal.

9. The system of claim 7 , wherein the first and second expandable rolls each comprise a piezoelectric crystal material, a ceramic material, or a combination thereof.

10. The system of claim 7 , comprising an electrical system configured to apply the electrical signal to the first expandable roll while suspending application of the electrical signal to the second expandable roll, and configured to apply the electrical signal to the second expandable roll while suspending application of the electrical signal to the first expandable roll.

11. The system of claim 7 , wherein the first drive roll, when in operation, is configured to drive the welding wire in a first direction, and wherein the second drive roll, when in operation, is configured to drive the welding wire in a second direction opposite the first direction.

12. The system of claim 7 , wherein the first drive roll is fixed to a first gear, the second drive roll is fixed to a second gear, and the first and second gears are synchronized with one another.

13. The system of claim 12 , comprising a motor coupled to the first gear, the second gear, or both and configured to drive the first gear, the second gear, or both, wherein the motor, when in operation, is configured to rotate only in one direction during operation of reciprocating welding wire feed system.

Assignees

• Illinois Tool Works

Inventors

• Hsu Christopher
• Sigl Dennis
• Bankstahl Herbert Alexius

Classifications

• B23K9/125 Primary

  Feeding of electrodes (for stabilising arc B23K9/073) · CPC title

• B23K9/124 Primary

  Circuits or methods for feeding welding wire · CPC title

• B23K9/133

  Means for feeding electrodes, e.g. drums, rolls, motors · CPC title

• B23K9/1336

  Driving means · CPC title

• B65H51/10

  with opposed coacting surfaces, e.g. providing nips · CPC title