SENSOR FOR WELD WIRE SUPPLY DRUM

A sensor system detects the level of weld wire in a supply drum used in a manual, automated, or robotic welding operation. The system includes a pair of sensors on the exterior of the drum and which illuminate a light in one color to indicate a sufficient supply of weld wire and then a second color to indicate a low or depleted level of weld wire within the drum. The sensor system will start and stop the welding operation, depending upon the level of weld wire within the drum. The system can also send a notification to a remote operator as to the level of wire in the drum.

FIELD OF THE INVENTION

This invention generally relates to the field of welding, including manual, automated, and robotic particularly the invention is directed to a sensor system for weld wire supply drums used with welding machines and/or at welding stations. The invention monitors the level of weld wire in the drum utilizing one or more sensors mounted to the exterior of the drum.

The system includes a light operatively connected to the sensor which illuminates to indicate the level of wire in the drum. For example, a green light indicates a sufficient supply of weld wire to proceed with the welding operation, and a red light indicates a low or depleted supply of weld wire, which precludes the weld operation from proceeding. The system can also send a signal to a remote operator to notify the operator of a low or depleted supply of weld wire.

BACKGROUND OF THE INVENTION

Manual, automated, and robotic welding is well known for many applications and in many industries. A conventional weld station typically includes a drum or container for holding the weld wire to be used in the welding operation. In prior art welding stations, the drum must be periodically manually inspected to check the level of the weld wire. When the weld wire is depleted, the operation must be stopped until a new supply of weld wire is provided in the drum. Such down time interrupts and slows productively, which is undesirable. If an automated or robotic machine continues without wire, the weld will not be complete, and the process will have to be reset after wire is added to the drum. Such operation can lead to incomplete weld beads or overlapping beads, neither of which is desirable.

Therefore, there is a need in the industry for a means and method of notifying an operator or personnel when the weld wire supply in the drum becomes low or depleted.

Accordingly, a primary objective of the present invention is the provision of a sensor system for a weld wire supply drum which automatically provides a visual indication of the level of weld wire in the drum.

Another objective of the present invention is the provision of a sensor system which can be retrofit to an existing weld wire supply drum.

Another objective of the present invention is the provision of a weld wire supply drum sensor system which automatically notifies an operator of the level of the weld wire in the supply drum.

Still another objective of the present invention is a provision of a sensor system for a weld wire supply drum which eliminates the need to manually check the level of weld wire in the drum.

A further objective of the present invention is the provision of a weld wire sensor system which can notify a remote operation when the weld wire level becomes low.

Still another objective of the present invention is the provision of a sensor system which can be retrofit to an existing weld wire supply drum to sense the wire level in the drum.

Yet another objective of the present invention is the provision of a weld wire sensor systems which automatically stops the welding machine when the weld wire reaches a pre-determined level in the supply drum.

Another objective of the present invention is the provision of a weld wire sensor system which is easy to install, and simple and accurate in use.

These and other objectives have become apparent from the following description of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS AND PHOTOGRAPHS

The sensor system of the present invention is generally designated by the reference numeral10in the drawings, and is configured or adapted for use with manual, automated, and robotic welding operations. The sensor system10is mounted on a weld wire supply drum12of a welding machine or station. Typically, the side wall of the drum12is made of cardboard. The drum12has a removable cover or lid16to allow weld wire18to be loaded into the drum12.

The sensor system10includes a housing20which is mounted to the drum side wall14in any convenient manner, such as strafes, adhesive, or fasteners. The housing10has an upper sensor22and a lower sensor24. In the preferred embodiment, the sensors22,24are inductive proximity sensors. One example of the sensors22,24is Model No. IME30-38NPSZC0S sold by SICK, Inc.

Sensors22,24are electrically coupled to a light26on the top of a post28extending upwardly from the housing20. Preferably, the light26is a color-changing LED.

In operation, the sensor system10provides a visual indication of the level of weld wire18in the drum12. For example, when there is a sufficient supply of wire18in the drum12to perform the welding operations, both sensors22,24detect the presence of the wire in the drum, and send a signal to the light26, which may be illuminated green, indicating that it is okay to proceed or continue the welding operation. As the welding operation uses the weld wire, the level of wire18in the drum12drops below the upper sensor22, as shown inFIG. 2, which generates a different signal for the light26, which changes to a different color, such as yellow, indicating a low level of wire in the drum. If the wire18is depleted to a level below the lower sensor24, as shown inFIG. 3, a third signal is sent to the light26, which again changes color, such as red, indicating an insufficient supply of weld wire to continue the welding operation.

As an alternative or in addition to the light26, the sensor system10may include an audible indicia. For example, an alarm or other sound can be emitted from a speaker to indicate a low or exhausted supply of weld wire.

The sensor system10provides multiple functions. First, the system10provides a visual indication of the wire level in the drum, with a color of the light indicating whether the level is good, low, or out. The sensor system10provides a quick and simple visual indicia to an operator as to the level or status of weld wire18in the drum12. When the level becomes low or exhausted, the operator can change the empty drum out with a new full drum, thereby minimizing down time for the welding operation and maximizing proactivity.

Secondly, the sensor system10can be connected to the controls of the automated/robotic welding machine so as to automatically stop the machine or prevent start of the operation when the weld wire level in the drum is low or out, as sensed by the sensors22,24. This function prevents the welding operation from proceeding if there is insufficient weld wire to complete the operation.

Thirdly, the system10can be connected to the welding machine controls and monitoring software to send notifications to personnel in a remote location or who otherwise cannot see the color of the light26, and thereby allow someone to reload the drum with additional wire before the wire is completely depleted.