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Wire Feeding System Disclosure Number: IPCOM000239461D
Publication Date: 2014-Nov-10
Document File: 81 page(s) / 5M

Publishing Venue

The Prior Art Database


A system for automated welding comprises a bulk pack with welding wire, a welding torch and a wire guiding system for guiding the welding wire from the bulk pack to the welding torch. A wire feeder is being used which advances the welding wire or at least assists another wire feeder in advancing the welding wire. The feeder can be controlled depending on parameters such as a voltage signal present at the welding wire, or a signal from an encoder arranged close to the welding torch. The wire feeder can also provide data related to the consumption of the welding wire, based on the amount of welding wire advanced. An operator interface allows adjusting the feeder to the particular circumstances.

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Wire Feeding System

  The innovation relates to a wire feeding system, in particular for feeding welding wire.

  Generally speaking, the innovation conveniently uses the welding wire itself as the means through which the signal for starting and stopping the rear booster

assisting device, which acts in a manner similar to the known booster feeders, by detection and consequent instantaneous reaction to any type of signal transmitted through the welding wire itself. In a preferred embodiment, the signal can be the voltage passing through the welding wire as soon as the welding power source or welding machine, supplies tension and the welding arc is struck

improving the accuracy of the wire boost and increasing the booster motor lifespan, with an efficiency comparable to the conventional synchronization between feeder and booster.

  Additionally, in a preferred embodiment, the controlling booster software can be programmed to adjust the motor working torque and partially or completely

wire electrode; consequently, the main wire feeder simultaneously starts pulling


is being transmitted from the front feeder to the auxiliary wire feeder (booster). This permits eliminating the use of hampering cables and to save the cost of the motion detecting device, regardless of the distance between the front pulling feeder and the back booster and the length or the path of the wire guiding liner.

The innovation is based on the idea of actively controlling a wire feed



at the welding torch tip, but also any other type of power line transmitted frequency signal between the front feeder and the feed assisting booster. The detection of this signal is immediate and allows to promptly start or stop the booster motor torque in connection with the actual welding action, thus preventing unnecessary and dangerous overheating of the rear booster unit, 20


stop the boosting motor torque immediately after the interruption of the welding arc or after an adjustable lapse of time.

  In the GMAW (gas metal arc) and other welding processes, as soon as welding voltage and current is supplied by the welding machine and the welding arc is struck, a tension varying from 10 to 40 Volts, travels through the welding 30

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and feeding wire from the bulk container into the welding torch, since the two actions are inter-connected. The present innovation detects and advantageously exploits the presence or absence of tension signal on the welding wire, which is the equivalent of the start or stop of the main feeder, and simultaneously translates it, through the booster components and software, into a command to


start or stop of the rear booster motor torque. Since the rear booster and the front main feeder are not connected and the two speeds are not synchronized, the booster software can perform a variety of additional functions like, for example, controlling the motor torque and pushing a bit more than the front feeder in order to compensate the backlash...