SELF-ADJUSTING WIRE FEEDER MOUNTING ASSEMBLY

Abstract

A self-adjusting wire feeder mounting assembly includes a mount fixedly connectable to a multi-axis robotic arm, and a slidable, floating adapter plate for mounting of a wire feeder thereon. The adapter plate is coupled with and slidable about the mount, and the adapter plate is moveable relative to the mount when a force is applied to the wire feeder.

Claims

1-11. (canceled)

12. A wire feeder mounting assembly for a robotic welding torch, comprising: a mounting bracket fixedly connectable to a robotic arm of the robotic welding torch; a moveable adapter plate configured to mount a wire feeder; a stationary track coupling the mounting bracket to the moveable adapter plate, the stationary track being defined by one or more stationary bolts, the moveable adapter plate being moveable along said stationary bolts; and one or more resilient members biasing said moveable adapter plate relative to the mounting bracket, each of the one or more stationary bolts extending through at least one of the one or more resilient members.

13. The wire feeder mounting assembly of claim 12, wherein the moveable adapter plate further includes a flange having one or more openings through which the one or more stationary bolts extend.

14. The wire feeder mounting assembly of claim 13, wherein a bearing is disposed in each of the one or more openings to facilitate movement of the moveable adapter plate along the one or more stationary bolts.

15. The wire feeder mounting assembly of claim 13, wherein the moveable adapter plate includes a mounting surface configured to mount the wire feeder and a lower surface opposite the mounting surface, the flange extending from the lower surface.

16. The wire feeder mounting assembly of claim 12, wherein each of the one or more stationary bolts has an end that is screwed into and fixedly connected to said mounting bracket such that a shank of each bolt extends outwardly from only one same side of the mounting bracket.

17. The wire feeder mounting assembly of claim 12, wherein the moveable adapter plate is configured to move in a first direction and a second direction opposite the first direction.

18. The wire feeder mounting assembly of claim 12, wherein the one or more resilient members comprise one or more coil springs.

19. A robotic welding torch, comprising: a robotic arm; a welding torch mounted to the robotic arm; a power cable connected to the welding torch at a first end; and a wire feeder connected to power cable at a second end opposite the first end, the wire feeder being mounted to a wire feeder mounting assembly, the wire feeder mounting assembly comprising: a mounting bracket fixedly connected to the robotic arm, a moveable adapter plate, the wire feeder being mounted to the moveable adapter plate, a stationary track coupling the mounting bracket to the moveable adapter plate, the stationary track being defined by one or more stationary bolts, and the moveable adapter plate being moveable along said stationary bolts, and one or more resilient members biasing the moveable adapter plate relative to said mounting bracket, each of the one or more stationary bolts extending through at least one of the one or more resilient members.

20. The robotic welding torch of claim 19, wherein the moveable adapter plate further includes a flange having one or more openings through which the one or more stationary bolts extend.

21. The robotic welding torch of claim 20, wherein the moveable adapter plate includes a mounting surface configured to mount the wire feeder and a lower surface opposite the mounting surface, the flange extending from the lower surface.

22. The robotic welding torch of claim 19, wherein each of the one or more stationary bolts has an end that is screwed into and fixedly connected to said mounting bracket such that a shank of each bolt extends outwardly from only one same side of said mounting bracket.

23. The robotic welding torch of claim 19, wherein the moveable adapter plate is moveable towards or away from the welding torch.

24. The robotic welding torch of claim 19, wherein the one or more resilient members comprise one of the one or more coil springs.

25. The robotic welding torch of claim 19, wherein the power cable extends through or along the robotic arm.

26. A method of adjusting a position of a wire feeder of a robotic welding torch, the method comprising: moving a welding torch of the robotic welding torch about an axis of rotation, the welding torch being connected to a power cable, and the movement of the welding torch changing a tension of the power cable; and moving a wire feeder in response to the change in tension of the power cable, the wire feeder being connected to the welding power cable and mounted on a moveable adapter plate configured for movement along a stationary track defined by one or more stationary bolts, wherein moving the wire feeder comprises moving the moveable adapter plate toward or away from the welding torch along the stationary track.

27. The method of claim 26, wherein the stationary track couples the moveable adapter plate to a mounting bracket fixedly attached to the robotic arm.

28. The method of claim 27, wherein each of the one or more stationary bolts has an end that is screwed into and fixedly connected to said mounting bracket such that a shank of each bolt extends outwardly from only one same side of said mounting bracket.

29. The method of claim 26, wherein the moveable adapter plate further includes a flange having one or more openings through which the one or more stationary bolts extend.

30. The method of claim 26, wherein each of the one or more stationary bolts extend through one or more resilient members.

31. The method of claim 26, wherein the power cable extends through or along a robotic arm of the robotic welding torch.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the drawings:

[0014] FIG. 1 is a schematic view of a robotic MIG welding torch and mounted wire feeder according to the prior art;

[0015] FIG. 2 is a schematic view of a robotic MIG welding torch system showing cooperative movement of a robotic arm and wire feeder of the system;

[0016] FIG. 3 is an exploded view of a self-adjusting wire feeder mounting assembly of the robotic MIG welding torch system;

[0017] FIG. 4 is a perspective view of the self-adjusting wire feeder mounting assembly in a fully extended disposition;

[0018] FIG. 5 is a perspective view of the self-adjusting wire feeder mounting assembly in a fully retracted disposition;

[0019] FIG. 6 is a side view of the self-adjusting wire feeder mounting assembly mounted on a robotic arm and in the fully extended disposition; and

[0020] FIG. 7 is a side view of the self-adjusting wire feeder mounting assembly mounted on the robotic arm and in the fully retracted disposition.

DETAILED DESCRIPTION OF THE INVENTION

[0021] With reference to FIG. 2, a robotic welding torch system 30 disclosed includes a multi-axis controllable robotic arm 32. A welding torch 34 is mounted on a distal end 36 of the robotic arm 32 via an end effecter or other mounting structure. A welding power cable 38 is connected on one end to the welding torch 34. The power cable 38 extends through or along the robotic arm 32. The opposite end of the power cable 38 is connected to a wire feeder 44. The power cable 38 may be a unicable or similar multipurpose cable which transmits welding power and consumable electrode welding wire from the wire feeder 44 to the welding torch 34. The wire feeder 44 is floatably mounted on the robotic arm 32 such that the forces exerted on the power cable 38 by movement of the robotic arm 32 push and pull the wire feeder 44 back and forth to relieve stress in the power cable.

[0022] Turning to FIGS. 3-5, the wire feeder is floatably mounted on the robotic arm by a self-adjusting wire feeder mounting assembly 46. In one embodiment, the wire feeder mounting assembly 46 includes a slidable, floating adapter plate 48 having an upper mounting surface 50 on which the wire feeder is mounted. The wire feeder 44 is fastened to a mounting plate 52, and the mounting plate is in turn fastened to the adapter plate 48 via through-holes 54 in the adapter plate. The mounting plate 52 may be feeder specific, i.e. designed to mount a specific make and/or model of wire feeder. The wire feeder 44 is shown in a partial cutaway view in order to expose the fastening of the wire feeder to the mounting plate. Alternatively, the wire feeder 44 may be directly mounted on the adapter plate.

[0023] The adapter plate 48 is coupled with and slidable relative to a stationary mount, such as mounting bracket 56, via a linear track. Specifically, one or more flanges 58 extend from a lower surface of the adapter plate 48 (opposite the upper mounting surface 50). The flange(s) 58 include opening(s) 60. A shoulder bolt 62 is inserted through each opening 60 and screwed into a corresponding aperture 64 in the mounting bracket 56. The shanks of the shoulder bolts 62 define the linear track on which the adapter plate slides. A bearing 66 may be disposed in each opening 60 to facilitate movement of the adapter plate 48 along the shoulder bolts 62. Resilient members 68 such as coil springs or similar are disposed on the shanks of the shoulder bolts 62 on both sides of the flange(s) 58. The resilient members 68 bias the adapter plate 48 in forward and backward directions as the adapter plate moves along the shoulder bolts 62.

[0024] The mounting bracket 56 is fixedly connected to an exterior of the robotic arm 32 such as a location proximate a rear, shoulder end of the arm as shown in FIGS. 6 and 7. For example, the mounting bracket 56 includes apertures 70 through which fasteners 72 such as SHCS (socket head cap screw) type fasteners or similar attach the mounting bracket to the robotic arm. The mounting bracket 56 may be robot specific, i.e. designed to mount on a specific make and/or model of robotic arm.

[0025] The self-adjusting mounting assembly 46 provides for slidable movement of the wire feeder relative to the robotic arm. As the robotic arm 32 moves about its axes (for example as shown schematically by two-headed arrow 74 in FIG. 2), force is exerted on the power cable 38 that extends through the robotic arm. This force acts upon the wire feeder 44 at the end of the power cable to either push the wire feeder backward away from the robotic arm 32 or forward toward the robotic arm 32 (as shown schematically by two-headed arrow 76 in FIG. 2). The self-adjusting mounting assembly 46 can move between a fully extended disposition as shown in FIGS. 4 and 6 and a fully retracted disposition as shown in FIGS. 5 and 7. For example, when a force is applied by the power cable 38 against the wire feeder 44 (in a direction away from the robotic arm 32) caused by compression of the power cable, the adapter plate 48 slides linearly in the same direction backwards away from the robotic arm. The resilient members 68 on the back side of the flange(s) 58 are compressed by the applied force. When the force is removed, the resilient members 68 return to their uncompressed, resting state, thereby sliding the adapter plate 48 linearly in a forward direction back toward the robotic arm 32. Similarly, if the power cable 38 applies a pulling force to the wire feeder 44 (in a direction toward the robotic arm 32), the adapter plate 48 slides linearly in the same direction toward the robotic arm. The resilient members 68 on the front side of the flange(s) 58 are compressed by the applied force. When the force is removed, the resilient members 68 return to their uncompressed, resting state, thereby sliding the adapter plate 48 linearly in a backward direction away from the robotic arm 32. Since the floating wire feeder absorbs the forces exerted on the power cable (by utilizing those forces to move the adapter plate 48 along the shoulder bolts 62), the power cable does not bind, snap, or stretch within the robotic arm. This reduces wear of the power cable and reduces premature failure of the power cable.

[0026] Although the assembly has been described by reference to a specific embodiment, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the assembly not be limited to the described embodiment, but that it have the full scope defined by the language of the following claims.