Method And Apparatus For Welding With Mechanical Arc Control

Abstract

A method and apparatus for feeding wire from a source of wire to a weld includes one or more motors disposed adjacent the wire to drive the wire to the weld. A buffer is disposed between the source and an arc end of the torch. Another motor may be disposed near the wire source. A wire tension controller may be provided. The one or more motors advance and retract the wire, and wire is stored, or the path length altered, when the wire is retracted.

1 . A system for feeding wire from a source of wire to a weld, comprising: 
 at least one motor disposed adjacent the wire and disposed to drive the wire to a torch; and    a buffer disposed between the source and an arc end of the torch.    
   
   
       2 . The wire feeder of  claim 1 , wherein the buffer includes a wire liner and the wire is disposed within the liner at least a portion of the distance from the source to the torch.  
   
   
       3 . The wire feeder of  claim 2 , wherein the liner is disposed within a tube, such that the path of the liner within the tube can be increased or decreased, relative to the tube length.  
   
   
       4 . The wire feeder of  claim 3 , wherein the tube has an inner diameter that is substantially more than an outer diameter of the liner.  
   
   
       5 . The wire feeder of  claim 3 , wherein the buffer includes a shaft with a hollow path therethrough, wherein the wire follows the hollow path, and the tube is mounted to the shaft, such that the tube moves with the shaft relative to the wire.  
   
   
       6 . The wire feeder of  claim 2 , wherein the buffer includes a shaft with a hollow path therethrough, wherein the wire follows the hollow path, and the liner is mounted to the shaft, such that the liner moves with the shaft relative to the wire.  
   
   
       7 . The wire feeder of  claim 2 , wherein the liner is compressible.  
   
   
       8 . The wire feeder of  claim 7 , wherein the liner is a coil spring.  
   
   
       9 . The wire feeder of  claim 1 , further comprising a sensor disposed to sense the length of wire in the buffer.  
   
   
       10 . The wire feeder of  claim 1 , wherein the at least one motor disposed adjacent the wire is one of a stepper motor, a servo motors, a zero backlash motor, or a gearless motor.  
   
   
       11 . The wire feeder of  claim 1 , wherein the at least one motor disposed adjacent the wire includes a wire feed motor closer to the source than to the torch, and a stepper motor, a servo motors, a zero backlash motor, a gearless motor, or a linear actuator closer to the torch than the source.  
   
   
       12 . The wire feeder of  claim 1 , wherein the at least one motor includes a pair of motors disposed on opposite sides of the wire.  
   
   
       13 . A system for feeding wire from a source of wire to a weld, comprising: 
 at least one motor disposed adjacent the wire and disposed to drive the wire to a torch; and    a wire tension controller, disposed adjacent the wire and between the source and an arc end of the torch.    
   
   
       14 . The wire feeder of  claim 13 , further comprising a wire tension sensor, disposed to provide a tension feedback signal to the tension controller.  
   
   
       15 . The wire feeder of  claim 13 , wherein the at least one motor disposed adjacent the wire is one of a stepper motor, a servo motors, a zero backlash motor, or a gearless motor.  
   
   
       16 . The wire feeder of  claim 13 , wherein the at least one motor disposed adjacent the wire includes a wire feed motor closer to the source than to the torch, and a stepper motor, a servo motors, a zero backlash motor, a gearless motor, or a linear actuator closer to the torch than the source.  
   
   
       17 . The wire feeder of  claim 13 , wherein the at least one motor includes a pair of motors disposed on opposite sides of the wire.  
   
   
       18 . A method of feeding wire from a source of wire to a torch, comprising: 
 driving the wire toward and away from the torch; and    when the wire is driven away from the torch, storing a length of wire between the source and an arc end of the torch.    
   
   
       19 . The method of  claim 18 , wherein storing includes moving the wire relative to a liner disposed about the wire.  
   
   
       20 . The method of  claim 19 , wherein storing further includes moving the liner within a tube, such that the path of the liner within the tube is increased or decreased, relative to the tube length.  
   
   
       21 - 81 . (canceled)