Abstract:
Exemplary embodiments of the present technique relate to a welding storage structure. In one embodiment, a welding system includes a welding chassis and a storage structure that rotates outwardly from the welding chassis. In another embodiment, a welding system includes a welding storage unit having a storage base with a plurality of storage compartments, a cover removably disposed over the plurality of the storage compartments, and a rotatable chassis mount configured to couple the welding storage unit rotatably to a welding chassis.

Description:
BACKGROUND 
       [0001]    Welding systems generally include a variety of items that are either consumed or worn during welding operations. In addition, certain welding operations involve an exchange of one or more items with alternatives having different sizes, shapes, and other features. The items may include welding wire electrodes and welding gun parts, such as seals, contact tips, and nozzles, among others. For example, welding operations may consume one or more electrodes and wear components due to thermal, electrical, and mechanical fatigue, stresses, friction, and so forth. By further example, a particular welding operation may involve exchanging one contact tip with another having a larger or smaller diameter passage to receive a particular electrode. Unfortunately, existing welding systems do not provide easily accessible and secure storage areas dedicated to these items. As a result, the items are often misplaced or lost, causing substantial delays and increased costs. 
       BRIEF DESCRIPTION 
       [0002]    Exemplary embodiments of the present technique relate to a welding storage structure. In one embodiment, a welding system includes a welding chassis and a storage structure that rotates outwardly from the welding chassis. In another embodiment, a welding system includes a welding storage unit having a storage base with a plurality of storage compartments, a cover removably disposed over the plurality of the storage compartments, and a rotatable chassis mount configured to couple the welding storage unit rotatably to a welding chassis. 
     
     
       DRAWINGS 
         [0003]    These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0004]      FIG. 1  is a perspective view of a welding system having a front storage apparatus disposed in a folded or rotatably retracted position in accordance with an exemplary embodiment of the present technique; 
           [0005]      FIG. 2  is a partial side view of the welding system as illustrated in  FIG. 1 , further illustrating an embodiment of the front storage apparatus disposed in an unfolded or rotatably extracted position; 
           [0006]      FIG. 3  is a partial side view of the welding system as illustrated in  FIG. 1 , further illustrating an embodiment of the front storage apparatus disposed in an unfolded or rotatably extracted position with a cover disposed in an open position; 
           [0007]      FIG. 4  is a top view of an embodiment of the front storage apparatus as illustrated in  FIG. 1  without the cover; 
           [0008]      FIG. 5  is a perspective view of an embodiment of the front storage apparatus with the cover disposed in a closed position; and 
           [0009]      FIG. 6  is a perspective view of an embodiment of the front storage apparatus with the cover disposed in the open position. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    Referring generally to  FIG. 1 , this figure depicts an exemplary portable arc welding system  10  having a welding chassis  11  with a front storage apparatus  12 . As discussed in further detail below, the front storage apparatus  12  may be self-contained, removable, and rotatable relative to the welding chassis  11 . For example, the front storage apparatus  12  may be rotated or generally pivoted inward and outward from the chassis between folded and unfolded positions relative to the chassis  11 . In the illustrated embodiment, the folded position is generally upright or vertical along the front of the chassis  11 , while the unfolded position (see  FIGS. 2 and 3 ) is generally protruding outward or horizontal relative to the front of the chassis  11 . The front storage apparatus  12  also may include a substantially or entirely self-enclosed storage volume independent from the chassis  11 . Thus, the front storage apparatus  12  may be released and removed from the chassis  11 , while still containing various items within the self-enclosed storage volume. In the illustrated embodiment, the front storage apparatus  12  is generally dedicated to the storage of consumables, wear items, replacement items, and other items that may be generally exchanged for a particular welding operation. In the following discussion, the term consumables may include electrodes, welding gun parts, fittings, seals, sleeves, collars, contact tips, nozzles, and other parts that may be replaced prior to or in the course of a welding operation. 
         [0011]    In addition, the front storage apparatus  12  may include one or more informational labels, which may include text, figures, symbols, codes, and other information relevant to replacement parts, welding parameters, or generally operating or servicing the welding system  10 . As discussed below, the informational labels also may be thermally, chemically, or materially fused into the interior and/or exterior of the front storage apparatus  12 , e.g., without use of glue, tape, or adhesives. 
         [0012]    The disclosed embodiments of the front storage apparatus  12  may be manufactured with a variety of welding power units, wire feed mechanisms, or general welding systems, including arc welding systems, gas welding systems, and so forth. In the illustrated embodiment of  FIG. 1 , the welding system  10  includes a wire feeder  13  having a wire spool  14  disposed within the welding chassis  11 . The welding system  10  also includes a welding current source or power unit  15 , which may include one or more control units or circuit boards and associated automatic and manual controls. The wire feeder  13  receives an electrode wire  16  from the wire spool  14  and generally drives or forces the electrode wire  16  into and through a welding cable  18  to a welding gun  20 . In the illustrated embodiment, the electrode wire  16  has a generally tubular shape and a metallic composition. A flux also may be disposed within the tubular metal electrode wire  16 . Eventually, the electrode wire  16  passes through and protrudes from a welding contact tip and nozzle assembly  22 , where the peripheral end or tip of the electrode wire  16  melts with a work piece  24  as an arc forms during a welding operation. In certain embodiments, the wire feeder  13  may be separate from the welding chassis  11 . In other embodiments, the wire feeder  13  may be excluded and the welding system  10  may utilize stick electrodes. 
         [0013]    A welding circuit is set up as follows. The welding cable  18  has conductors for transmitting current or power from the power unit  15  of the welding system  10  to the welding gun  20 . The welding gun  20 , in turn, transmits the current or power to the contact tip in the contact tip and nozzle assembly  22 . The work piece  24  is electrically coupled to one terminal of the power unit  15  by a ground clamp  26  and a ground cable  28 . Thus, an electrical circuit between the work piece  24  and the power unit  15  is completed when the electrode wire  16  of the welding gun  20  is placed in proximity to, or in contact with, the work piece  24 , and the welding gun  20  is engaged to produce an arc between the wire  16  and the work piece  24 . The heat produced by the electric current flowing into the work piece  24  through the arc causes the work piece  24  to melt in the vicinity of the arc, also melting the electrode wire  16 . Thus, the arc generally melts a portion of the work piece  24  and a tip portion of the welding wire  16 , thereby creating a weld with materials from both the work piece  24  and the welding wire  16 . 
         [0014]    In the illustrated embodiment, gas  30  stored in a gas cylinder  32  is used to shield the molten weld puddle from impurities. For example, the gas cylinder  32  feeds gas  30  to the wire feeder  13 . The gas  30  is fed, along with the electrode wire  16 , through the welding cable  18  to the neck of the welding gun  20 . The inert shield gas  30  prevents impurities entering the weld puddle and degrading the integrity of the weld. However, other shielding techniques, such as flux, may be used in certain embodiments of the welding system  10 . 
         [0015]    During operation, the welding contact tip and nozzle assembly  22  may be subjected to high temperatures, thermal fatigue, and friction wear by the electrode wire  16  passing through the contact tip. The welding gun  20  also may include additional elements, such as valves, rings, seals, shielding gas lenses screws, nuts and so forth. These and other items associated with the welding gun  20  may be consumable items, or wear items, or exchangeable items depending on a particular welding operation. As noted above, the front storage apparatus  12  may store one or more of these various items. 
         [0016]    The welding system  10  of  FIG. 1  further includes a front bezel  40  having control knobs and/or control gauges  42 , which may be coupled to the power unit  15 , the wire feeder  13 , and one or more controllers, circuit boards, and other internal components. The control knobs and/or gauges  42  may generally control and/or measure parameters, such as shielding gas flow and pressure, wire feed speed, voltage, and current. 
         [0017]    The front bezel  40  further includes the front storage apparatus  12  disposed between two front handles  46 . In the illustrated embodiment, the front storage apparatus  12  is disposed at the front of the welding chassis  11  and at a height above the ground, permitting the welder convenient access to the front storage apparatus  12 . The front storage apparatus  12  includes a storage tray or base  44  coupled to the chassis  11 , and a cover  62  (see  FIGS. 5-6 ) coupled to the storage base  44 . In this manner, the front storage apparatus  12  has a storage volume or space that is a self-contained by the storage base  44  and the cover  62 . In other words, the self-contained inner space or storage volume of the front storage apparatus  12  is independent and distinct from the space of the welding chassis  11  and various components (e.g., power unit  15  and wire feeder  13 ) disposed in the welding chassis  11 . As mentioned above, the illustrated front storage apparatus  12  may be hingedly, rotatably, or generally pivotably coupled to the chassis  11 , such that the front storage apparatus  12  can rotate between folded and unfolded positions relative to the chassis  11 . In addition, the illustrated front storage apparatus  12  may be removable from the chassis  11 , thereby allowing access to the storage space away from the chassis  11 . The illustrated front storage apparatus  12  also includes a handle  48 , which may facilitate rotating the apparatus  12  relative to the chassis  11  and also carrying the apparatus  12  when removed from the chassis  11 . 
         [0018]    As mentioned above, the front storage apparatus  12  also may include one or more labels, such as an external label  49 . The label  49  may include text, graphics, symbols, and general information pertaining to welding parameters, charts, replacement parts, and contents of the front storage apparatus  12 . In certain embodiments, the label  49  may be integrally fused into the front storage apparatus  12  without any glue or adhesives. For example, the label  49  may be a plastic sheet that is placed in a mold cavity being filled with a plastic material to form the shape of a portion of the storage apparatus  12 , e.g., the storage base  44 . Thus, the heat of plastic injected into the mold cavity causes the plastic sheet of the label  49  to generally melt or thermally fuse with the plastic in the mold. 
         [0019]    The front storage apparatus  12  is adapted to store a variety of welding items, such as replacement contact tips and/or nozzles  22  of the welding gun  20 , the neck  19  of the welding gun  20 , gas valves, clamps  26 , o-rings, seals, fasteners, and various sizes and shapes of these parts. The front storage apparatus  12  may also contain tools used during welding tasks, parts replacement or exchange tasks, servicing tasks, and so forth. These tools may include screwdrivers, drills, markers, wire cutters, files, pliers, socket sets, and wrenches. 
         [0020]    Turning now to  FIG. 2 , this figure is a partial side view  50  of the arc welding system  10  as illustrated in  FIG. 1 , further illustrating rotational positions of the front storage apparatus  12  relative to the chassis  11 . Specifically,  FIG. 2  illustrates two rotational positions  44   a  and  44   b  of the front storage apparatus  12  relative to the front bezel  40  of the arc welding system  10 . In the illustrated embodiment, the front storage apparatus  12  can be moved about a rotational axis between at least two locked or secure rotational positions, including an unfolded position or rotatably extracted position  44   a  (solid lines) and a folded position or rotatably retracted position  44   b  (dashed lines). The front storage apparatus  12  is rotatable between these two positions  44   a  and  44   b  as indicated by arrow  52 . In addition, as illustrated in  FIG. 2 , the folded or rotatably retracted position  44   b  is generally recessed into a cavity within the front bezel  40  in a generally upright or vertical orientation, whereas the unfolded position  44   a  is extended outward from the front bezel  40  in a generally protruding or horizontal orientation. 
         [0021]    The front storage apparatus  12  may be unfolded or extracted away from the front bezel  40  by initially pulling on the handle  48 , thereby unlatching or generally releasing the front storage apparatus  12  from the front bezel  40  in the locked folded position  44   b . In other words, the front storage apparatus  12  and/or the handle  48  may include a latch, snap-fit mechanism, hook, or other tool-free fastener that engages with a mating fastener on the front bezel  40 . Subsequently, the front storage apparatus  12  may rotate downward toward the unfolded position  44   a  via gravity and one or more resistive mechanisms, such as a coil spring, a hydraulic mechanism, or another force in the opposite direction. Thus, the resistive mechanism may enable a smooth or generally slow movement of the front storage apparatus  12  from the folded position  44   b  to the unfolded position  44   a . In one or both of the positions  44   a  or  44   b , the front storage apparatus  12  may be locked in place to prevent inadvertent upward or downward movements relative to the chassis  11 . In certain embodiments, the front storage apparatus  12  may include a keyed lock, a combination lock, a magnetic lock, or another security mechanism to secure the contents of the front storage apparatus  12 . 
         [0022]    The front storage apparatus  12  as illustrated in  FIG. 2  includes a pair of prongs  54  disposed on an outer edge of a pair of opposite supporting arms  56  of the storage base  44 . The prongs  54  mate with prong receptacles, grooves, or pathways in the chassis  11  to enable rotation of the front storage apparatus  12  between the positions  44   a  and  44   b  as indicated by arrow  52 . In other words, the mating between the prongs  54  and the prong receptacles represent a rotational axis, or hinge axis, or general pivot axis between the front storage apparatus  12  and the chassis  11 . In certain embodiments, the prongs  54  may move along a linear path, or a curved path, or both as the front storage apparatus  12  rotates betweens the positions  44   a  and  44   b . When the storage base  44  is disposed in the unfolded position  44   a , the prong  54  may be disposed at a position labeled  54   a . When the storage base  44  is in the folded position  44   b , the prong may be disposed in a position labeled  54   b . As depicted in  FIG. 2 , movement of the front storage apparatus  12  as indicated by arrow  52  or vice versa may corresponds to lateral, vertical, and curved motion of the prong  54  between the positions  54   a  and  54   b . In certain embodiments, a plastic bezel  51  may provide a stop for the prongs  54  when those move between the positions  54   a  and  54   b.    
         [0023]    As further illustrated by  FIG. 2 , when in the folded position  44   b , the front storage apparatus  12  may be almost completely flush with the front bezel  40 . When in the unfolded position  44   a , the front storage apparatus  12  extends almost completely beyond the front bezel  40  of the arc welding system  10  so that the top of the storage base  44  may be completely exposed and easily accessible. 
         [0024]      FIG. 3  is a partial side view  60  of the arc welding system  10  as illustrated in  FIGS. 1 and 2 , further illustrating the rotational positions  44   a  and  44   b  of the front storage apparatus  12  relative to the chassis  11  and an open position of the cover  62  relative to the storage base  44 . Specifically,  FIG. 3  further illustrates the cover  62  rotatably coupled to the storage base  44  via hinge  64 . The cover  62  may be opened or closed as it moves along an arc labeled by arrow  66 . The cover  62  includes a latch  68 , used to secure the cover  62  to the storage base  44  once the cover  62  is in a closed position. Once opened, the cover  62  maintains an upright and vertical position such that it does not close back down on the storage base  44 . Further, once the cover  62  is opened, inner compartments of the storage base  44  may become fully exposed so as to provide the welder comfortable access to the consumable welding materials disposed in the inner compartments of the storage base  44 . 
         [0025]      FIG. 4  is a top view of an inner storage arrangement or compartmental configuration  70  of the storage base  44  in accordance with an exemplary embodiment of the present technique. The compartmental configuration  70  of the storage base  44  includes compartments  72   a - 72   d  and  74 , which may include different shapes and sizes according to the type of consumable materials stored in the storage base  44 . Accordingly, compartment dividers  76  and  78  may be configured to be modular such that their placement within the storage base  44  may correspondingly adapt the storage base  44  spatially. In this manner, inner space of the storage base  44  may be optimized to the particular welding consumables, wear items, replacement parts, and so forth. Further, each of the compartments  72   a - 72   d  and  74  securely holds the consumable welding materials and parts in designated places within the storage base  44 . This may reduce the likelihood of undesired mixing of the contents as the welding system  10  may be shifted, for example, during transit between welding job sites. 
         [0026]    In the illustrated embodiment, the supporting arms  56  may flex so as to induce lateral motion of the prongs  54 . Such flexibility may enable the prongs  54  to detach from or attach to the chassis  11 . This may enable the welder to carry the storage base  44  away from the chassis  11  to a more convenient location, such as a work bench, to facilitate repair, servicing, replacement of parts, and other assembly or disassembly of the welding gun  20  with the items in the storage base  44 . Accordingly, the illustrated front storage apparatus  12  may include a carrying handle  79  disposed on a rear side of the storage base  44  between the supporting arms  56 . 
         [0027]      FIG. 5  is a perspective view of front storage apparatus  12  having the cover  62  disposed in a closed position over the storage base  44  in accordance with an exemplary embodiment of the present technique. As discussed above with reference to  FIG. 3 , the cover  62  pivots about the hinge  64  as it opens or closes relative to the storage base  44 . Further, the cover  62  includes the handle  48  used for opening the cover  62  relative to the storage base  44  as illustrated in  FIGS. 5-6  and, also for rotating the front storage apparatus  12  between the folded and unfolded positions  44   b  and  44   a  relative to the chassis  11  as illustrated in  FIGS. 2 and 3 . When in a closed position, the cover  62  securely seals the storage base  44  such that materials disposed within the storage base  44  are not displaced and/or thrown out from the storage base  44 . Again, the cover  62  may be latched or generally secured to the storage base  44  in the closed position, for example, by a snap-fit mechanism, a hook and slot, and compression fit, and so forth. 
         [0028]    The cover  62  further includes one or more cover labels  80  disposed on the outer surface of the cover  62 . The cover label  80  may include a variety of information, such as a company logo, address, contact information, welding parameters or settings, illustrations, and other useful information. For example, the cover label  80  may include a list of electrode wires, wire feed settings, gas flow settings, power output settings, and other parameters for a particular application. Accordingly, prior to a welding operation, a welder can utilize the label  80  to prepare appropriate welding materials, as well as configure the welding system  10  according to various specifications dictated by the nature of the welding operation. 
         [0029]    The storage base  44  and the cover  62  may be generally formed via injection of a molding material, e.g., plastic, into a suitable molding cavity. Accordingly, the label  80  may be thermally or materially fused with the cover  62  during the molding process. For example, the label  80  may be a plastic sheet, which is placed in the molding cavity prior to filling the cavity with a hot molding material. Upon filling the cavity with the hot molding material, the heat causes the label  80  to thermally fuse with the molding material eventually solidifying as the cover  62 . As a result, the label  80  is integral with the cover  62  without any intermediate adhesives or glue. Molding the label  80  to the cover  62  in such a manner may reduce the likelihood of the label  80  wearing out or generally falling off of the cover  62  over time. Alternatively, the label  80  may be affixed with the cover  62  via an adhesive disposed between the top surface of the cover  62  and the label  80 . 
         [0030]      FIG. 6  is a perspective view of the front storage apparatus  12  having the cover  62  disposed in an open position relative to the storage base  44  in accordance with an exemplary embodiment of the present technique. As illustrated in  FIG. 6 , the latch  68  of the cover  62  is disposed along a central portion of a peripheral edge of the cover  62 . The illustrated latch  68  has a generally v-shaped geometry, which may be flexible and resiliently compressible to facilitate latching with a mating portion  81  of the storage base  44 . For example, the latch  68  may compress and bias a latch feature  83  against a mating feature  85  in the mating portion  81  of the storage base  44  when the cover  62  is closed onto the storage base  44  as illustrated in  FIG. 5 . In this manner, the latch  68  secures the cover  62  to the storage base  44 , while the cover  62  is in a closed position. The cover  62  may be unlatched by pushing the latch inwardly to disengage the latch feature  83  from the mating feature  85 .  FIG. 6  further illustrates the manner by which inner compartments of the storage base  44  are fully exposed when the cover  62  is disposed in the open position. 
         [0031]    Disposed on an inside surface of the drawer cover  62  is a label  82 . The label  82  may include text  84  and illustrations  86  pertaining to consumable welding material and parts. The illustrations  86  may include, for example, graphical illustrations or exploded views of the welding gun  20  and its components. The items shown in the illustrations  86  may include consumable welding items, wear items, or exchangeable welding items to be stored in the front storage apparatus  12 . Accordingly, the illustrations  86  may be accompanied by text  84 , which may provide information for each part of the welding gun  20  depicted in the illustrations  86 . For example, the text  84  may include part numbers, part names, reference numbers corresponding to the illustrations  86 , and so forth. Thus, the text  84  and the figures  86  of the label  82  may serve the welder as a reference guide when locating, inspecting, replacing, exchanging, ordering, or generally looking for information about parts and consumables associated with the welding system  10  and the welding gun  20 . Additional text and/or figures  88  may further be inscribed on the label  82  to include additional specifications relating to welding consumable materials and their use during in a welding operation. The label  82  may be affixed, adhered, or thermally fused to the inner surface of the cover  62  in a manner similar to that described above with reference to the label  80  of  FIG. 5 . 
         [0032]    Again, the front storage apparatus  12  of the disclosed embodiments enables quick and easy access to various welding items without interference with other functional parts of the welding system  10 , such as the power unit  15 , the wire feeder  13 , and so forth. The front storage apparatus  12  also provides a multi-stage securing system, which includes the closed position of the cover  62  over the storage base  44  (see  FIG. 5 ) and also the folded position  44   b  of the front storage apparatus  12  relative to the chassis  11  (see  FIG. 1 ). As a result, the front storage apparatus  12  can be self-contained independent from the chassis  11 , and can be removed from the chassis  11 . The front storage apparatus  12  also has a relatively small foot print or horizontal space consumption in both the folded and unfolded positions  44   b  and  44   a  largely due to the rotational mounting of the front storage apparatus  12  with the chassis  11 . Thus, the rotational nature of the front storage apparatus  12  is particularly useful in crowded work areas. 
         [0033]    While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.