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Wire Feed System and Method of Controlling Feed of Welding Wire Disclosure Number: IPCOM000241229D
Publication Date: 2015-Apr-07

Publishing Venue

The Prior Art Database


A wire feeding system, in particular for feeding a so called "cold wire" or wire with no Tension nor signal running on its surface, in which the pulling or holding of the wire by the front wire feeder puts the rear pushing slave Booster respectively into a pre-set active full Motor torque or into a pre-set stand-by minimum motor torque, as needed. Alternatively, a wire feed system for feeding a so called "cold wire" or wire with no tension nor signal running on ist surface, in which the rear pushing slave booster is remotely controlled by an optic sensor positioned nearby the torch and sensing the light of the torch welding or spraying arc.

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Wire Feed System and Method of Controlling Feed of Welding Wire

Field of the Invention

  The invention relates to a wire feeding system, in particular for feeding cold welding wire or metal spray wire or any other wire in applications where there is no presence of current (voltage) or any other type of signal running on the wire itself during use.

Further, the present invention relates to a method of controlling feed of

welding wire.


  Wire feeding systems are commonly used for feeding welding wires from a supply source, for example a container in which a significant amount (up to

torch. The passing of the welding wire through the inevitable bends and curvatures on the wire guiding liner conduit necessarily creates a certain amount of friction and drag. More curves along the wire guiding liner conduit can worsen the problem to the point that it becomes very difficult for the wire feeding system to function properly and to guarantee the necessary smooth feeding.

  In conventional welding applications, a single feeding device pulls the wire from the container and feeds it to the welding torch and it is placed between the wire storage or source (the container) and the welding torch (the consumer). In




several hundred kilograms) of welding wire is being stored, to a point called welding arc where the welding wire is being deposited through a welding torch, with the purpose of joining metal parts. Since the welding torch is usually connected to a welding robot and continuously moving, the welding wire has to be fed through a wire guiding liner conduit from the container to the welding 20


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some other welding applications the feeding device itself contains the wire source in the form of a small spool and feeds the wire to the welding torch.

  In robotic and automated applications, which are designed to maximize the productivity, the trend goes towards using large bulk packs containing from few hundred kilograms to more than one ton of welding wire. These bulk containers


have to be positioned in a safe area at a significant distance from the device feeding the welding wire to the welding torch and preferably on the floor in a location that can be easily accessed by a forklift. In order to comply with increasingly stricter safety regulations and standards, it is strongly advisable to refrain from placing containers with welding wire high on top of traveling robots,


where the maneuver of replacing a used pack with a new one can represent a serious hazard for the robot operators and weight tolerances would only permit the use of containers carrying a limited quantity of welding wire. Placing the packs at the floor undoubtedly offers the significant advantages of making it possible to use heavier containers with more product, for a maximized downtime


saving, and of working in a safer environment but it can result in the welding wire having to be pulled over significant distances by the front feeder de...