WIRE GUIDE MODULE AND SYSTEM

A plurality of wire guide modules are interconnected and pivotally attached to each other. The wire guide modules are pivotable between straight configuration and a curved configuration. Each wire guide module defines a channel (22) extending longitudinally therethrough with bearings (24, 26, 28) on opposite lateral sides of the channel. The wire guide modules are defined by first (10a) and second (10b) halves that are joined together to define the channel and retain the bearings. Each wire guide module defines a slot portion (40a) at a first end and tongue portion (42a) at the second end. The tongue portion is sized to be received within the slot portion. The tongue portion defines a pivot hole and the slot portion defines pivot pins received in the pivot hole to define the pivot axis therebetween.

FIELD

The present disclosure relates to a wire guide module for use in a wire dispensing system. More particularly, the present disclosure relates to a flexible guide module for use with large diameter wire.

BACKGROUND

Welding systems, such as MIG welding systems, include the use of a consumable electrode that is fed from a wire storage container to a weld gun. The consumable electrode is heated and melted at the location where welding is desired, such that wire is constantly fed to the weld gun during the welding process when welding is occurring.

In some instances, the location of the weld gun and the welding operation can be located remotely relative to the wire storage container. Accordingly, the wire may be fed over a large distance to ultimately reach the location of the weld gun. Accordingly, a guiding structure through which the wire travels may be used. However, at extending lengths, friction can build up along the wire, requiring greater force to feed the wire or potentially damaging the wire due to the contact with the wire guide.

Additionally, the wire may need to fed in opposite directions through the guide depending on the state of the system. Wires can be of various diameter depending on the type of weld gun and size of the weld being created. Larger diameter wires can be more difficult to feed than smaller diameter wires, having greater weight as well as surface area, and being more difficult to bend, which increases friction on the wire, especially around bends, and/or when the feed direction is reversed.

There remains a need for a wire guide module which enables the direction of a wire in a wire dispensing system to be changed without substantially increasing the drag on the wire and for use with large diameter wires.

SUMMARY

According to an aspect, a wire guide module for feeding large diameter wire is provided, including: a housing having a having a first end and a second end, wherein the main body extends longitudinally between the first end and the second end; a slot portion defined at the first end of the housing; a tongue portion defined at the second end of the housing, the tongue portion having a thickness generally corresponding to a space defined by the slot portion, such that the tongue portion of the module is receivable within the slot portion of an identical further housing; a first port defined at the slot portion and a second port defined at the tongue portion and a channel extending longitudinally from the first port to the second port for feeding the wire therethrough; wherein the channel includes a central section extending parallel to the longitudinal axis of the housing and the channel further includes a tapered portion extending from the central section toward the first port or the second port; at least two rotatable bearings disposed in the main body on opposite lateral sides of the channel, wherein the bearings are configured to contact and feed the wire through the channel.

In one aspect, the housing defines a first edge and second edge on opposite lateral sides of the housing, wherein the first edge has a concave curvature and the second edge has a convex curvature.

In one aspect, the tapered portion of the channel defines opposing first and second tapered edges, wherein the second tapered edge extends parallel to the central section of the channel and the first tapered edge extends at an oblique angle relative to the central section in a direction toward the first edge of the housing.

In one aspect, the at least two bearings comprise three bearings, wherein a first bearing is disposed on a first side of the channel closest to the first edge of the housing, and second and third bearings are disposed on a second side of the channel closest to the second edge.

In one aspect, the first, second, and third bearings are equally spaced relative to each other.

In one aspect, the first bearing is disposed longitudinally between the second and third bearings.

In one aspect, the first port is an outlet port and the second port is an inlet port.

In one aspect, first port is recessed relative to the first end and the second port is flush with the second end.

In one aspect, the housing includes a first half and a second half joined together at a mating plane, wherein the channel is defined by both the first half and the second half.

In one aspect, the first half and second half are mirrored shapes across the mating plane.

In one aspect, the tongue portion is defined by both the first half and the second half, wherein the first and second halves each include a tongue flange that meets at the mating plane.

In one aspect, the slot portion is defined by both the first half and the second half, wherein the first and second halves each include a slot flange that are spaced apart on opposite sides of the mating plane.

In one aspect, the tongue portion includes a pivot hole extending through the flange portion and a curved slot extending through the flange portion, wherein the slot portion includes a post and a pin, wherein the post is sized to be received in the pivot hole of another module and the pin is sized to be received and moveable within the curved slot of another module.

In one aspect, the pivot hole, curved slot, pin, and post are on the same lateral side of the channel.

In one aspect, the curved slot is laterally offset relative to the pivot hole, and the pin is laterally offset relative to the post.

In another aspect, a flexible wire guide module system includes: a plurality of interconnected wire guide modules including at least a first wire guide module and a second wire guide module, each wire guide module of the plurality of interconnected wire guide modules including: a slot portion defined by a pair of slot flanges at a first longitudinal end of the module; a tongue portion defined by a pair of tongue flanges at a second longitudinal end of the module; a module channel extending between a first port at the first and a second port at the second end; a plurality of bearings disposed within the module adjacent the module channel including at least one bearing on each lateral side of the module channel; wherein the first and second modules are pivotally connected via a positive connection fit between the tongue portion of the first module and slot portion of the second module; an overall channel comprising each of the module channels, wherein the overall channel changes depending on a relative orientation of each module.

In one aspect, the plurality of modules are pivotally adjustable between a straight configuration and a curved configuration.

In one aspect, each module is pivotable relative to an adjacent module in only a single direction relative to the straight configuration.

In one aspect, the system includes a first terminal attached to a first end of the plurality of modules and a second terminal attached to a second end of the plurality of modules, wherein the first and second terminals each include a port for receiving or providing a wire therethrough, wherein the first terminal includes a tongue portion in a positive connection fit with the slot portion of the wire guide module at the first end, and the second terminal includes a slot portion in a positive connection fit with the tongue portion of the wire guide module at the second end.

In another aspect, a method of interconnected a plurality of wire guide modules is provided. The method includes the steps of: providing a first half of a wire guide module, wherein the first half includes a slot flange at a first end and a tongue flange at a second end, wherein the slot flange includes post projecting therefrom and the tongue flange defines pivot hole extending therethrough; placing a plurality of bearings adjacent a channel defined in part by the first half and extending longitudinally between the first end and the second end, wherein the bearings are placed on opposite lateral sides of the channel; providing a second half of a wire guide module, wherein the second half includes a slot flange at a first end and a tongue flange at a second end, wherein the slot flange includes a post projecting therefrom and the tongue flange defines pivot hole extending therethrough; attaching the second half of a wire guide module to the first half and capturing the bearings therebetween, wherein the tongue flanges of the first and the second half combine to define a combined tongue portion defining a combined pivot hole therethrough; in response to attaching the second half to the first half, defining an assembled first wire guide module; after defining the first wire guide module, attaching a further first half of a wire guide module to the combined tongue portion by inserting the post of the further first half into the combined pivot hole of the combined tongue portion; attaching a further second half of a wire guide module to the combined tongue portion by inserting the post of the further second half into the combined pivot hole of the combined tongue portion; disposing further bearings between the further first and second halves; in response to attaching the further first and second halves to the combined tongue portion and disposing further bearings therebetween, defining a further combined wire guide module; wherein the first wire guide module and the further wire guide module are pivotally connected in positive locking engagement therebetween.

DETAILED DESCRIPTION

Referring initially toFIGS.1and2, a single wire guide module10is shown. It will be appreciated that this wire guide module10can be connected to additional wire guide modules of the same construction in a chained manner, as further described below. Initially, the single wire guide module10will be described.FIG.1illustrates a wire guide module10with terminal portions12and14attached to opposite ends of the module10. In the case of multiple modules chained together, the terminals12and14may be attached to opposite ends of the chain of connected modules, as further described below.

FIG.2illustrates a cross-sectional view ofFIG.1, and illustrates internal components of the wire guide module10as well as the terminals12,14. The cross-section is taking along a central longitudinal plane of the wire guide module10and terminals12,14. As further described below, the terminals12,14may connect to opposite ends of the module10or the chain of modules10in a positive locking manner such that portions of the terminals12,14are received within the ends of the wire guide module10or chain of modules10, and vice versa. This positive connection can be seen inFIG.2.

Here, the wire guide module10generally has a first end11that extends longitudinally towards a second end13. The wire guide module10may have a first surface15(or lower edge15) and a second surface17(or upper edge17) that also extend between the first end11and the second end13on generally opposing sides of the wire guide module10. In this example, the first surface15may be substantially convex in shape. The second surface17may be flat or may be slightly concave in shape.

In one aspect, multiple wire guide modules10may be connected together to define an elongated guide path for a wire to be fed therethrough. The wire guide modules10are sized and arranged to be moveable relative to each to define various orientations and curvatures relative to each other in order to define a path for the wire along a desired curvature.

FIG.5illustrates a chain110of wire guide modules10connected together to define a straight path.FIG.6illustrates an end view of the chain of modules10and showing a clear path extending therethrough.FIG.7illustrates the chain110in a curved and straight configuration extending between terminals12and14.FIG.8illustrates an end view of the curved and straight configuration ofFIG.7.FIG.9illustrates this curved and straight configuration attached to a cable carrier.

In one aspect, shown inFIGS.5and6, the wire guide modules10may be oriented and arranged to define generally straight path, with each wire guide module10feeding into an adjacent wire guide module10such that the wire does not bend or turn as it travels through the modules10. It will be appreciated that some slight bending or bowing of the wire may naturally occur even when the wire is being fed along a straight path.

As shown inFIG.5, a series of wire guide module10are connected end-to-end. Put another way, the right side or end13of the module10at the far left side of the series of modules10is attached to the left side or end11of the immediately adjacent module10in the figure. As shown, the upper edge17of the modules10generally define a straight path, with a series of small curvatures or indentations centered on each modules10.

Moving from left to right along the series of modules10inFIG.5along the upper edges17, the left side of the module10defines a convex outer curvature, which smoothly transitions into concave curvature along the midsection of the module10, which then smoothly transitions into convex curvature, which overlaps with the adjacent connected module10. Adjacent modules continue to overlap at the convex portions, and the concave portions at the midsection generally do not overlap along the upper edges17of the series of modules10.

Thus, the upper profile of the series or chain110of connected modules10defines a generally undulating profile/edge when the modules10are aligned in a straight path as shown inFIG.5. The degree of undulation is evenly distributed. Put another way, a straight notational line may be drawn tangential to the outermost portion of each of the modules10. Similarly, a straight notational line may be drawn tangential to the innermost portion of the modules10when the modules10are aligned in the straight arrangement. These lines are evenly spaced along the length of the chain110and parallel when the chain110is straight as shown inFIG.5.

The lower edges15are distinguishable from the upper edge17, in that the midsection of each module10is convex, and the convex curvature extends continuously between the terminal ends11,13of each module10. Thus, when aligned in the straight arrangement, a recess15ais defined at the overlap of the modules10. The recess15ahas a generally V-shape, which can be defined as a sharp corner or a concave profile with a pointed base.

Similar to the upper edge of the series of modules, the notational lines may be drawn through various corresponding structure along the series of modules10. For example, when in the straight configuration, a notational line drawn through the base of the recesses15adefined by the overlaps of the modules10will be straight. A notational line drawn through the outermost point of the modules10will be straight.

As the modules10are attached together in series, the modules10are pivotable relative to each other. In one aspect, the series of modules10may be bent relative to each other to define a 180 degree turn, as shown inFIG.7. Put another way, a wire being fed through the modules10in a first direction will be caused to bend and turn back to be fed in a second direction opposite the first direction.

In one aspect, the modules10may be arranged relative to each other such that a predetermined number of modules10, when pivoted a maximum amount relative to each other, define a 180 degree bend. In one aspect, eight (8) modules10may be attached in series to define a 180 degree turn,

When the modules10are in a curved configuration to define the 180 degree turn, the module10may combine to define curved inner profile110athat is substantially smooth and free from recesses, bumps, waves, indentations, or the like, as shown inFIG.7. In one aspect, the modules10may combine to define a semi-circular profile110athat is smooth and without said recesses or indentations.

In the curved configuration, an outer profile110bmay be defined that includes a plurality of outer recesses15b, similar to the v-shaped recesses previously described for the straight profile. The outer recesses110cin the curved configuration may have a smaller depth than the outer recesses15athat are defined between the modules10in the straight configuration.

In the curved configuration, a radiused notational line may be drawn along the inner edge of the modules10, with the radiused notational line substantially overlying the entire edge17of multiple modules10. This notational line may define a first diameter. In one aspect, the first diameter is 17.165 inches.

In the curved configuration, an outer radiused notional line may be drawn through the outermost point of the modules10, intersecting each module at a single point. In one aspect, the outer radiused notational line may have a diameter of 23.450 inches.

While both a straight configuration and a 180 degree curved configuration have been shown and described, it will be appreciated that other intermediate configurations may also be created, by varying the amount of relative pivoting between each module10. When each of a group of modules10are pivoted the same amount, the defined curvature will be relatively the same. In another aspect, the modules10may be pivoted relative to each other at different amounts, thereby creating a complex curvature that varies its radius. In one aspect, when the modules10defining the curvature are pivoted the same amount, internal channel22defined by the modules10for feeding the wire will have a generally constant radius along the curved path. When the modules10are pivoted at different degrees relative to each other, the internal channel22may have a varying radius.

The wire guide module10may include input port18as well as output port16. Located between input port18and output port16is channel22. Channel22extends from output port16to input port18. In one example, the wire may be fed through input port18through channel22all the way to output port16.

In one aspect, output port16may be recessed relative to the corresponding end13of the module10, with input port18being generally adjacent the corresponding end11of the module10. It will be appreciated that input port18and output port16are so described in relation to a given feed direction of the wire. However, the wire may be reversed in its feed direction, or the wire may be initially fed through the modules10in an opposite direction. Accordingly, input port18and output port16may also be referred to as first port18and second port16, respectively. Thus, second port16may be recessed relative to its corresponding edge, and first port18may be disposed generally adjacent its corresponding edge.

In one aspect, first port18may define a tapered shape, such that an outermost portion of first port18is wider than an innermost portion of first port18. Second port16, on the other hand, may have a generally constant width. First port18and second port16may also define a portion of the length of channel22, with an intermediate portion of channel22connecting first port18and second port16.

A first edge18bof the tapered shape may be aligned with the straight path for the wire when the modules10are in the straight configuration. When the modules10are in the straight configuration, a second edge18a, opposite the first edge18b, may be arranged at an oblique angle relative to the straight path of the wire. Accordingly, the first edge18bof the first port18is generally aligned with the second port16of the adjacent module10when the modules10are in the straight configuration.

When the modules10are in the curved configuration, the second edge18ais aligned with the curved path of the wire. The first edge18bis aligned at an oblique angle, generally tangentially, to the curved path of the wire. Accordingly, the second edge18ais generally aligned with the second port16of the adjacent module10when the modules10are in the curved configuration.

The second port16can be generally non-tapered, at least relative to the tapered shape of the first port18. This is because the second port16is recessed from the edge of the module10. When the modules are assembled, the first ports18are made to meet with the recessed second ports16. Put another way, when the modules10pivot relative to each other, the second port16can be said to remain fixed, with the first port18shifting relative to the fixed second port16inside of the module10that contains the fixed second port16. Alternatively, because the movement of the modules10are relative to each other, the first port18can be said to be fixed, with the second port16, which is disposed outside of the profile of the module10having the adjacent first port18, pivoting or shifting along the relatively wide opening of the first port18.

Whether straight or curved, the wire may be fed through the series of connected modules10in both directions through the series or chain110of modules10. Put another way, the wire may be fed through the inlet port18toward the outlet port16or each module, such that the wire enters the wide and tapered shape of the inlet port18, and exits the straight and narrow end of the outlet port16, and is then fed into the adjacent inlet port18, which is aligned with the outlet port16regardless of being straight or curved relative to each other. The wire may therefore also be fed in the opposite direction into the narrow opening of the outlet port16, through the module10, and out of the wide and tapered opening of the inlet port18, and into adjacent outlet port16, regardless of straight or curved configuration.

The primary feed direction of the wire may be in either direction relative to the series of modules10, and the wire may be backed-up opposite the primary feed direction, if necessary. The wire may therefore be pushed or pulled through the series of modules10. The modules10are arranged such that the wire will pass through the series of modules10with reduced friction or resistance, regardless of direction of feed and regardless of being pushed or pulled. It will be appreciated that resistance may still vary depending on direction and whether the wire is pushed or pulled.

Located within the wire guide module10are bearings24,26, and28, shown inFIG.2. The bearing24may be located on one side of the channel22, while bearings26and28may be located on an opposite side of the channel22. As such, as the wire is fed through the channel22, the bearings24,26, and/or28have the ability to reduce friction to allow the wire to travel through the wire guide module10more easily.

As shown inFIGS.2and2A, each module10may include the three bearings24,26,28. Bearing24is disposed on a lateral side of the module10that is adjacent the radially inner side of the module10when the series110of modules10are disposed in their curved configuration. Bearing24may therefore be referred to as inner bearing24, or may also be referred to as first bearing24.

Bearings26and28are opposite inner bearing24. When the modules10are in the curved configuration, the bearings26,28are on the radially outer side of the modules10. Accordingly, the bearings26and28may be referred to as outer bearings26and28, and may also be referred to as second bearings26and28.

Bearings24,26, and28are arranged in an alternating fashion, with bearing24being disposed longitudinally between bearings26and28. Bearing24combines with bearings26and28, therefore, to effectively define an inlet and outlet within the cluster of bearings. Bearings26and28are on the same side of the wire when the wire is passing through the module. Bearing24is on the opposite side of the wire relative to the bearings26and28when the wire is passing through the module10.

Bearing24and28are disposed adjacent outlet port16, with bearing28being disposed longitudinally closer to the outlet port16. In one aspect, bearing28defines a portion of outlet port16. In a case where the wire makes contact with both bearings, a given point on the wire would make contact with bearing28prior to making contact with bearing24when entering the module via outlet port16.

Bearing24and26are disposed adjacent inlet port18In particular, bearings24and26are disposed adjacent the narrow end of the tapered shape of inlet port18. Wire passing through the bearings24,26will exit the central section of the module10and enter the tapered shape of inlet port18. Alternatively, wire passing through the tapered shape of the inlet port18(in a direction toward the bearings24,26) will reach the narrow end of the inlet port18prior to entering the bearings24and26. A given point on the wire will contact bearing24prior to contacting bearing26when the wire is moving from the outlet port18toward the tapered inlet port16. A given point on the wire will contact bearing26prior to contacting bearing24when the wire is moving from the inlet port18toward the outlet port16.

In one aspect, the bearings24,26,28are arranged in a triangular pattern, such that a rotational axis of each bearing24,26,28is spaced approximately the same distance from each of the other two bearings. Put another way, a notational line connecting each axis of the bearings24,26, and28will define an equilateral triangle.

In one aspect, when more than one adjacent modules10are connected and arranged in a “straight” configuration, the bearings26and28of the first module will be substantially aligned with the bearings26and28of the adjacent module10. Similarly, each of the bearings24of the adjacent modules10will be aligned. A notional line running through the pairs of bearings26,28will be parallel to a line running through the bearings24.

When modules10are arranged in a curved manner, bearings24will be radially inward from the wire passing through the modules10. Bearings26and28will be disposed radially outward from the wire passing through the modules10.

The straight and curved configurations of the modules10have been previously described. The shape of the modules10at opposite ends thereof can be arranged to physically limit the degree to which the modules10may pivot relative to each other. When the modules10are arranged in a straight configuration, respective edges15of the modules10may be in contact with each other and may bear against each other such that the modules10are preventing from pivoting beyond the straight configuration in the direction of the upper edges. The edges17of the modules may be spaced apart from each other, thereby allowing the modules10to pivot in the direction of the edges17(toward a curved configuration), such that the space between the adjacent edges17is taken up as the modules move. As the modules10are pivoted toward the curved configuration, the edges15of adjacent modules10will move away from each other, and will increase space therebetween as the modules10continue to pivot.

When the modules10have reached the curved configuration, the edges17of adjacent modules10will abut each other, preventing further pivoting and limiting the amount of curvature. The edges17that contact each other in either the straight or curved configuration are defined by the corresponding tongue and groove structures defined by the modules10that are correspondingly attached to each other when the modules10are linked in series. The structure of the tongue and groove portions of the modules10is described in further detail below.

The system may also include terminal members12and14attached to the respective ends of the series of modules10, with one attaching to the tongue portion of a module10at one end and the other attaching to the groove portion of a module10at the opposite end. Terminal portions12and14function so as to provide either an input for inserting a wire from the wire roll or as an output for providing the wire to the welding tool. Here, the terminal end14includes port37. The port37may be made of a metal, such as brass, so as to aid the insertion of the wire. The terminal portion12includes a port39that also may be made of brass. Again, the purpose of making the port39out of brass or any other metal is so to allow the easy ejection or insertion of the wire through the terminal end12. The terminal members12and14may include flange portions12aand14a, respectively, that can be fixed in place in the work area, allowing the modules10that are connected therebetween to slightly flex and bend while still delivering the wire from a predetermined inlet position to a predetermined outlet position as defined by the fixed position of the terminal members12and14.

The terminal end14may also include bearings36and38so as to reduce friction and promote the feeding of the wire through the module10or series of modules10, while the terminal end12may include bearings30and32to enhance the passage of the wire through the modules10by reducing friction. Bearings36and38may be opposite sides of the wire when the wire is passing through the system. Bearings30and32may also be on opposite sides of the wire. Bearings36and38may be offset relative to each other, such that a given point on the wire will contact bearing36at a different time relative to bearing38. Similarly, bearings30and32may be offset, with the wire contacting bearing32at a different time relative to bearing30. Which bearing is contacting first depends on the direction of movement of the wire. Bearings30and36are disposed closer to the respective ports of the terminal members12,14. Bearings32and38may be disposed closer to the attached module10. When the terminal members12and14are arranged in a straight configuration with the module10or modules10also in a straight configuration, the bearings32and38are aligned with bearings26and28of the modules10, and bearings30and36are aligned with bearing24.

As shown inFIG.2, terminal member14defines a tongue portion that is received in a groove/slot of module10. Terminal member12defines a groove or slot portion that receives a tongue portion of the module10. The tongue/slot configurations are described further below.

As stated before, the module10is configured to connect to other modules. In order for this to happen, the module10, on the end11may have a tongue42. On the other end13, the module10may have a slot40. The slot40generally has a cross-section such that the tongue42can fit into the slot40of another module10. As such, as best shown inFIG.3, modules10A,10B,100,10D, and10E can all connect to one another by inserting the appropriate tongue42into the appropriate slots40.

With reference toFIGS.2and3, therefore, the tongue42A may be received in slot portion of terminal12. Similarly, slot40E may receive tongue portion of terminal14.

Each module10in a series110of modules, in addition to being received in an adjacent module10, is also retained relative to an adjacent module10by the modules10themselves. The modules10are formed by combining two halves10aand10b, as shown inFIG.2A. It will be appreciated that the halves10a,10bmay not necessarily be symmetrical or perfectly half, but rather opposing portions that are joined together via fasteners or the like.

The passageway or channel22for the wire is defined by joining the halves10a,10btogether. Similarly, the cavities or recesses for retaining the bearings of each module10are defined by joining the halves together.

For purposes of discussion, the module10will be further described as having a tongue end (end11that defines tongue42) and a slot end (end13that defines slot40). The tongue end of the module10defines the tongue42when the halves are assembled, and the slot end of the module10defines the slot40when the halves are assembled. The halves10aand10bmay also be described as a first half10aand second half10b.

The first half10adefines a central mating plane/surface10cof the module10. The passageway22may be formed partially as a groove formed in this surface. A slot flange40aat the slot end of the module10is recessed relative to the mating surface40c, thereby defining a stepped surface and an open space into which a corresponding tongue42may be received. At the tongue end of the module10, tongue flange42ais generally coplanar with the mating surface10c. The thickness at the tongue42is less than the thickness of the central portion of the module. This reduced thickness portion of the tongue flange42adefines half of the tongue42, and is sized and arranged to be received in a corresponding space of the slot end of the adjacent module10.

The tongue flange42adefines a pivot hole42bin which a corresponding post40bfrom an adjacent module10is received. The post42bmay be hollow to allow for a fastener43to pass therethrough. Thus, the module10will pivot about this connection between adjacent modules10. The tongue flange42afurther defines a curved slot42cwith a radius centered on the pivot hole42b. The curved slot42chas a curved length that corresponds to the amount of pivoting desired/permitted between adjacent modules10. The curved slot42creceives a pin40cthat projects from the corresponding slot flange40aof the adjacent module10. When the modules10are straight, the pin40cis positioned at one of the end curved slot42c. When the modules10are curved and pivoted, the pin40cis positioned at the opposite end of the curved slot42c.

When a single module10is assembled, pins and posts from opposite slot flanges40awill be generally joined together at mating place10cto define a combined pin or post. Similarly, slots or holes within the tongue flange42awill join together to define a combined slot or hole. Thus, when a single module10is assembled, the module10will be generally prevented from being inserted into a module10or to receive another module10, because the tongue would impact the combined pin and post, and the combined pin and post could not be received into the combined slot or pivot hole.

Thus, to interlink a plurality of modules10, the plurality of modules10may be assembled with corresponding first halves being connected, followed by the installation of the second halves after the desired number of first halves have been connected.

In one example, a first half10ais provided for subsequent assembly with additional first halves10a. A further first half10ais provided and attached to the initial first half10a. The post40bprojecting from the slot flange40ais accessible, as is the hole42binto which the post40bis received. The curved slot42cof one of the halves10ais similarly placed over the pin40c.

With the pivot pins and posts received in the curved slots and pivot holes of the adjacent module10, adjacent modules10are connected, and the bearings24,26,28may be placed in their corresponding recess formed within the first halves10a. The bearings may be placed in the first halves10prior to connecting to adjacent first halves10a, or after the first halves10ahave been connected.

With the bearings24,26, and28disposed and retained in the first halves10a, the second halves10bmay be placed onto the connected adjacent first halves10a. An initial second half10bmay be placed onto one of the halves10a, such that the bearings24,26, and28are captured. The pivot hole42band curved slot42cof second half10bwill be aligned with the pivot hole42band curved slot42cof the corresponding first half10a. After this initial second half10bis placed on its corresponding first half10a, the pivot hole42band curved slot42cof this second half10bis exposed and accessible from the outer surface of this now assembled module10.

With the pivot hole42band curved slot42cexposed and accessible, a further second half10bmay be placed onto the initial assembled module10. The pivot pin and post that projected toward the module10are inserted into the exposed pivot hole and curved slot. This further assembled module10now has its own pivot hole and curved slot exposed for receipt of a pivot pin and post of yet another further second half10b.

This process of installing the second halves10bmay be repeated as necessary to fully enclose the bearings within the modules10.

In one aspect, the process of providing a first half10aand connecting a further first half10amay be done in a first direction (for example to left to right). The slot flange40aof the first module is exposed and presented for attachment to a further first module10. The tongue flange42aof the next module is placed on the slot flange40aof the initial first half10a, such that the further first half10ais to the right of the initial first half10a. The further first half10atherefore has its own slot flange40apresented and exposed for yet another first half10ato be added to the right. Accordingly, a chain of first modules10may be assembled in this first direction.

Subsequently, the second halves10bmay be installed onto this chain in a second direction that is opposite the first direction. For example, the second halves10bmay be added to the above described chain in a right to left direction, until the chain of modules10is completed.

In one aspect, the pins40cand posts40bthat are received in the corresponding holes or slots do not extend beyond the mating plane10cbetween the halves10a,10b. Put another way, without installation of the bearings, the chain of first halves10acould be slidable relative to the chain of the second halves10b. However, the bearings24,26,28have a height that extends across the mating plane, thereby retaining the chains of halves10,10brelative to each other during installation. The halves10a,10bmay be additionally secured together via a fastener of the like. The fastener may extend through the posts40bof each module's slot flange40a, which are positioned through the pivot holes42bof tongue flanges42a. The fasteners will hold the slot flanges together to hold the halves10a,10btogether, allowing the tongue42to pivot relative to the slot40.

In another aspect, one module10may be fully assembled, followed by assembly of another module10, etc. For example, a first half10amay be provided, and the bearings24,26,28may be placed therein. The second half10bof this module10may then be placed on the first half10ato enclose the bearings, thereby defining a completed tongue42of the module10, having the curved slot42cand the pivot hole42btherein.

Following assembly of the two halves10a,10b, another first half10amay be assembled on one side of the tongue portion of the previously assembled module10. The bearings24,26,28may be disposed within this first half10a, and then the second half10bmay be added to the assembly on the opposite side of the tongue portion of the previously assembled module10. The halves10a,10bmay be joined together by a fastener at the slot end of the module10. Following this assembly of the second module10, there are two modules10connected together, and the second module10presents a tongue42for a subsequent module to be attached to in the same manner as described above.

It will be appreciated that in this approach either the first half10aor the second half10bmay be first joined to the tongue42of the previously assembled module10in the chain of modules10, and that the bearings24,26,28can be placed in the cavity of either half10a,10b.

In another aspect, a combination of the above two assembly methods may be used, such as a chain halves10amay be assembled followed by a chain of second modules, ultimately creating an assembled tongue portion of a module10at the end of the chain, at which point a first and second half10a,10bmay be added to the end of the chain.

Furthermore, in each of the above assembly methods, the terminals12and14may be provided as the ends of the overall chain, and may therefore be assembled similarly (either at the end of a chain of halves or as the first/last assembled component in the chain). Similar to the modules10, the terminals12and14have bearings and metal ports disposed therein, and these bearings and ports are installed within one of the halves of the terminals12,14prior to installing the opposite half.

In one aspect, the terminal14defines a tongue portion with holes in which the pin/post of the slot40of the adjacent module10are received. Thus, the terminal14may be assembled first, followed by the adjacent module10being attached to the tongue portion of the of the terminal14. The halves of the terminals12and14may be joined together via fasteners or the like, similar to the modules10.

In one aspect, the holes in the tongue portion of terminal14are arranged such that the pin and post of the adjacent module10are received to prevent the adjacent module10from substantially moving or pivoting, as shown inFIG.2. The passageway22for the wire extending through the terminal14is straight and does not flare out, such that the passageway joins with the straight and non-tapered outlet of the module10. At the opposite side of the module10, the port18is tapered, allowing the wire to extend from the terminal12into the module10even if the terminal12is pivoted relative to the adjacent module10. As shown inFIG.2, because the module10has a curved slot42cat its tongue42and the terminal12provides a pin that can shift within the curved slot, the module10can pivot relative to the terminal12(which has slot flanges similar to the modules10). In one aspect, the terminal12may include a projection that matches the shape of the curved slot of the module10to prevent pivoting therebetween. However, because the module10has a tapered port adjacent the terminal12, a pivoted module10relative to terminal12does not affect the provision of the wire through of the module and the terminal12.

Of course, it will be appreciated thatFIG.2illustrates how terminal12and14may attached to the structure that is present at the opposite ends of the module10. Typically, multiple modules10will be chained together, such that terminals12and14are not attached to the same module10, but rather to the opposite ends of the chain of modules10, with terminal12(which defines a slot) joined with the tongue42of the last module10of the chain and terminal14(which defines a tongue) joined with the slot40of the last module10on the opposite end of the chain.

The chain of modules10allows adjacent modules10to pivot relative to each other, such that the chain of modules can bend and flex to accommodate various installation requirements and pathways. Additionally, the resulting bent pathway defined by the chain of modules10can accommodate feeding the wire in both directions, such as when the wire is reversed. When the wire is pulled through the chain of modules10from the outlet, the wire may be put in tension and exert a force in an inward direction and against bearings24through a curved portion of the chain110. When the wire is reversed, such as being pushed from the outlet end, the wire will bear against bearings26and28. in both cases, the resistance on the wire is reduced by the bearings inside the modules10and disposed substantially along the entire path of the chain of the modules10.

Similarly, wire being pulled from the inlet end will cause the wire to bear against bearing24, and wire being pushed from the inlet end will cause the wire to bear against bearings26and28.

As forces are exerted by the wire against the interior of the modules10, the modules10may flex slightly relative to each other by pivoting relative to the pivotal connection therebetween.

in one aspect, as shown inFIGS.4and9, the modules10may be connected to a cable carrier50, such as cable carrier sold by Igus, Inc. of East Providence, Rhode Island. The cable carrier50can provide a structure for attaching other cables or the like associated with the welding system. The cable carrier can provide support for the chain110of modules10and can be adjusted to correspond to the curvature and path defined by the chain110of modules.