Abstract:
The present invention is an apparatus and method for replacing used electrode tips of a TIG welder. The apparatus has a main housing structure with a socket adapter assembly that is operatively supported by the main housing structure. The socket adapter assembly is used to both remove and re-attach the gas shield and the electrode nut of the TIG welder. A vacuum tip suction device that is operatively supported by the main housing structure is used to both remove and install electrode tips for the TIG welder.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims priority from and is related to commonly owned U.S. Provisional Patent Application Ser. No. 62/025,672 filed Jul. 17, 2014, entitled: Method and Apparatus for Changing the Electrode Tip of a TIG Welder, this Provisional Patent Application incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention relates generally to welding devices, and more particularly to tools for the removal and/or installation of electrode tips into or from TIG welders. 
       BACKGROUND 
       [0003]    The present invention relates to welding apparatus and methods used in tungsten-inert-gas (TIG) welding of steel-based materials. 
         [0004]    Conventionally, structures made of steel-based materials, such as carbon steel or stainless steel as the base material, are welded using TIG welding processes. TIG welding is widely used as a method of welding structures requiring high reliability since the welding operation can be easily performed and the welded metal portion can be formed with high-quality. 
         [0005]    In TIG welding, a torch is connected to a remote power source by a flexible tube through which is passed a power lead and gas for creating an arc between a tungsten electrode and a work piece, while shielding gas passes around the arc. The tip of the electrode requires replacement over time. To date, this tip replacement has been a manual process which results in equipment downtime and safety issues during the replacement of the tip of the electrode being held by a robotic arm. 
         [0006]    Therefore, what is needed is a method and apparatus which can be used to replace the tip of a TIG welder. 
         [0007]    Nothing in the prior art provides the benefits attendant with the present invention. 
         [0008]    Therefore, it is an object of the present invention to provide an improvement which overcomes the inadequacies of the prior art methods and devices and which is a significant contribution to the advancement to the welding art using a TIG welder. 
         [0009]    Another object of the present invention is to provide an apparatus for replacing used electrode tips of a TIG welder comprising: a main housing structure; a socket adapter assembly operatively supported by said main housing structure; and a vacuum tip suction device operatively supported by said main housing structure. 
         [0010]    Yet another object of the present invention is to provide an apparatus for replacing used electrode tips of a TIG welder comprising: a lower housing structure; a first moveable slide operatively connected to said lower housing structure; a first cylinder operatively supported within said first moveable slide; an upper housing structure operatively supported by said first moveable slide; a socket adapter assembly within said upper housing structure; and a vacuum tip suction device operatively supported by said upper housing structure. 
         [0011]    Still yet another object of the present invention is to provide a method for replacing used electrode tips of a TIG welder comprising: providing a robotic arm, said robotic arm holding the TIG welder; moving the TIG welder into a tip change position; providing a main housing structure having a socket adapter assembly operatively supported by said main housing structure, and a vacuum tip suction device operatively supported by said main housing structure; unthreading a gas shield from the TIG welder using said socket adapter assembly; unthreading an electrode nut from the TIG welder using said socket adapter assembly; removing a used electrode tip from the TIG welder using said vacuum tip suction device; placing a new electrode tip into said electrode nut using said vacuum tip suction device; threading said electrode nut with said new electrode tip onto the TIG welder using said socket adapter assembly; and threading said gas shield onto the TIG welder using said socket adapter assembly. 
         [0012]    The foregoing has outlined some of the pertinent objects of the present invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings. 
       SUMMARY OF THE INVENTION 
       [0013]    The present invention provides an apparatus and method for removing used electrode tips from a TIG welder and replacing the used electrode tip with a new electrode tip. The apparatus and method provide a system that allows for greater reliability, reduces downtime and increases safety in the use a TIG welder. 
         [0014]    Another feature of the present invention is to provide an apparatus for replacing used electrode tips of a TIG welder. The apparatus has a main housing structure that can have a lower housing structure and an upper housing structure. A socket adapter assembly is operatively supported by the main housing structure. A vacuum tip suction device is operatively supported by the main housing structure. The apparatus can have an electrode tip magazine that is operatively supported by the main housing structure. The apparatus can have a sensor that is operatively connected to the electrode tip magazine. The apparatus can have a moveable arm that is operatively supported by the main housing structure. The apparatus can have a first motor that is operatively connected to the socket adapter assembly. The apparatus can have a second motor that is operatively connected to the socket adapter assembly. The apparatus can have a plurality of slides and cylinders that are operatively connected to the main housing structure. 
         [0015]    Yet another feature of the present invention is to provide an apparatus for replacing used electrode tips of a TIG welder. The apparatus has a lower housing structure. A first moveable slide is operatively connected to the lower housing structure. A first cylinder is operatively supported within the first moveable slide. An upper housing structure is operatively supported by the first moveable slide. A socket adapter assembly is within the upper housing structure. A vacuum tip suction device is operatively supported by the upper housing structure. The apparatus can have an electrode tip magazine that is operatively supported by the upper housing structure. The apparatus can have a sensor that is operatively connected to the electrode tip magazine. The apparatus can have a second moveable slide that is operatively connected to the first cylinder. The apparatus can have a moveable arm that is operatively supported by the upper housing structure. The apparatus can have a first motor that is operatively connected to the socket adapter assembly. The apparatus can have a second motor that is operatively connected to the socket adapter assembly. The apparatus can have a second cylinder that is operatively connected to the vacuum tip suction device. 
         [0016]    Still yet another feature of the present invention is to provide a method for replacing used electrode tips of a TIG welder. The method comprising the following steps: a robotic arm is provided that holds the TIG welder. The TIG welder is moved into a tip change position using the robotic arm. A main housing structure is provided. The main housing structure has a socket adapter assembly that is operatively supported by the main housing structure and a vacuum tip suction device that is operatively supported by the main housing structure. A gas shield is unthreaded from the TIG welder using the socket adapter assembly. An electrode nut is unthreaded from the TIG welder using the socket adapter assembly. A used electrode tip is removed from the TIG welder using the vacuum tip suction device. A new electrode tip is placed into the electrode nut using the vacuum tip suction device. The electrode nut is threaded with the new electrode tip onto the TIG welder using the socket adapter assembly. The gas shield is threaded onto the TIG welder using the socket adapter assembly. The used electrode tip can be placed into an empty holding position on an electrode tip magazine. A sensor can be used to locate the empty holding position on the electrode tip magazine. A first motor can be provided that is operatively connected to the socket adapter assembly. The gas shield can be unthreaded from the TIG welder using the first motor as operatively connected to the socket adapter assembly. A second motor can be provided that is operatively connected to the socket adapter assembly. The electrode nut can be unthreaded from the TIG welder using the second motor as operatively connected to the socket adapter assembly. The electrode nut with the new electrode tip can be threaded onto the TIG welder using the second motor as operatively connected to the socket adapter assembly. The gas shield can be threaded onto the TIG welder using the first motor as operatively connected to the socket adapter assembly. A moveable arm can be provided that is operatively supported by the main housing structure. The moveable can be used to knock stuck used electrode tips loose from the TIG welder. 
         [0017]    The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1A  is a side view of a TIG welder assembly; 
           [0019]      FIG. 1B  is an exploder view of a TIG welder; 
           [0020]      FIG. 1C  is a front view of a TIG welder assembly; 
           [0021]      FIG. 1D  is a side view of a TIG welder assembly; 
           [0022]      FIG. 2  is a back view of a TIG welder tip changing system according to one embodiment of the present invention; 
           [0023]      FIG. 3A  is a side view of a TIG welder tip changing system according to one embodiment of the present invention; 
           [0024]      FIG. 3B  is a front view of a TIG welder tip changing system according to one embodiment of the present invention; 
           [0025]      FIG. 3C  is a side view of a TIG welder tip changing system according to one embodiment of the present invention; 
           [0026]      FIG. 4  is a top view of a TIG welder tip changing system according to one embodiment of the present invention; 
           [0027]      FIG. 5A  is a front view of a TIG welder assembly engaged to a TIG welder tip changing system with an exploded view of the TIG welder according to one embodiment of the present invention; 
           [0028]      FIG. 5B  is a side view of a TIG welder assembly engaged to a TIG welder tip changing system according to one embodiment of the present invention; and 
           [0029]      FIG. 5C  is a perspective view of a TIG welder assembly engaged to a TIG welder tip changing system with an exploded view of the TIG welder according to one embodiment of the present invention. 
       
    
    
       [0030]    Similar reference characters refer to similar parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0031]    The present invention provides an apparatus and method for replacing a used electrode tip of a TIG welder with a new electrode tip. A typical TIG welder assembly  200  has a robotic arm holding the TIG welder  220  as shown in  FIGS. 1A to 1D . The robotic arm must be moved to a tip change position. The tip change position places the electrode tip over the present invention. Usually, a software routine can be initiated to move the robotic arm to the tip change position. 
         [0032]    As shown in  FIG. 2 , the present invention  10  is an apparatus that has a lower housing structure  12  and an upper housing structure  14 . The housing structures  12 ,  14  have a plurality of slides  20 ,  22  and cylinders  30 ,  32  (that can move up/down, left/right and rotationally, typically through a software routine) to move a first motor  40  to a first position to engage a gas shield  50  of the TIG welder  220  with a first socket adapter assembly  60 . 
         [0033]    Once the plurality of slides  20 ,  22  and cylinders  30 ,  32  start to move the first motor  40  into a first position, the first motor  40  starts to rotate in a first direction to unthread the gas shield  50  from the TIG welder  220 . At the completion of unthreading of the gas shield  50 , the plurality of slides  20 ,  22  and cylinders  30 ,  32  can move the first motor  40  to a second position. 
         [0034]    The plurality of slides  20 ,  22  and cylinders  30 ,  32  move the second motor  42  to the second position to engage an electrode nut  70  of the TIG welder  220  with the socket adapter assembly  60 . Once the plurality of slides  20 ,  22  and cylinders  30 ,  32  move the second motor  42  into the second position, the second motor  42  starts to rotate in a second direction to unthread the electrode nut  70  from the TIG welder  220  using the socket adapter assembly  60 . At the completion of unthreading the electrode nut  70 , the plurality of slides  20 ,  22  and cylinders  30 ,  32  can return the second motor  42  to the first position. 
         [0035]    The plurality of slides  20 ,  22  and cylinders  30 ,  32  are used to position an arm  80  that has a vacuum tip suction device  90  to the second position and to center the vacuum tip suction device  90  above an electrode nut position. The plurality of slides  20 ,  22  and cylinders  30 ,  32  move the second motor  42  with the removed electrode nut  70  up to the second position where the vacuum tip suction device  90  is used to grab a used electrode tip  100  from the TIG welder  220 . Using the plurality of slides  20 ,  22  and cylinders  30 ,  32 , the second motor  42  can be returned to the first position. 
         [0036]    Using the plurality of slides  20 ,  22  and cylinders  30 ,  32 , the second motor  42  is moved to the first position. The arm  80  that carries the vacuum tip suction device  90  returns to a third position with the used electrode tip  100 . The used electrode tip  100  is placed into an empty holding position on an electrode tip magazine  110 . A sensor and/or an encoder  120  can be utilized to locate an empty holding position on the electrode tip magazine  110  as shown in  FIG. 4 . The electrode tip magazine  110  can be moved, e.g., rotated, by being attached to the second motor  42  to assist the sensor and/or the encoder  120  in locating the empty holding position on the electrode tip magazine  110 . The electrode tip magazine  110  can be moved, e.g., rotated, by being attached to the second motor  42  to assist the sensor and/or the encoder  120  in locating a new electrode tip  101  on the electrode tip magazine  110 . Once the new electrode tip  101  is located, the vacuum tip suction device  90  is used to grab the new electrode tip  101 . The plurality of slides  20 ,  22  and cylinders  30 ,  32  are utilized to move the vacuum tip suction device  90  with the new electrode tip  101  from the third position to a fourth position and to center the new electrode tip  101  above the electrode nut position. The plurality of slides  20 ,  22  and cylinders  30 ,  32  are utilized to move the second motor  42  with the removed electrode nut  70  up to the second position. The vacuum suction tip device  90  releases the new electrode tip  101  and the new electrode tip  101  falls into the electrode nut  70 . 
         [0037]    In the event that a used electrode tip  100  sticks to the TIG welder  220  after the removal of the electrode nut  70 , the present invention provides an extra arm  130  for knocking the used electrode tip  100  loose from the TIG welder  220  as shown in  FIG. 4 . In one embodiment, the extra arm  130  is operatively supported by the upper housing structure  14  of the system  10 . 
         [0038]    The plurality of slides  20 ,  22  and cylinders  30 ,  32  move the second motor number  42  into the first position and the vacuum tip suction device  90  is moved to the third position. The plurality of slides  20 ,  22  and cylinders  30 ,  32  move the second motor  42  into the second position while the second motor  42  starts to rotate in a third direction to thread the electrode nut  70  onto the TIG welder  220 . The electrode nut  70  is then threaded onto the TIG welder  220  until a first specified torque is achieved, e.g., 200-210 N·cm. 
         [0039]    At the completion of threading the electrode nut  70  to the first specified torque, the plurality of slides  20 ,  22  and cylinders  30 ,  32  return the second motor  42  to the first position. The plurality of slides  20 ,  22  and cylinders  30 ,  32  move the first motor  40  into the second position while the first motor  40  starts to rotate in a fourth direction to thread the gas shield  50  onto the TIG welder  220 . The gas shield  50  in then threaded onto the TIG welder  220  until the second specified torque is achieved, e.g., 50-60 N·cm. At the completion of threading the gas shield  50  to the second specified torque, the plurality of slides  20 ,  22  and cylinders  30 ,  32  return the first motor  40  to the first position. The TIG welder  220  is now moved by the robotic arm holding the TIG welder  220  back to a TIG welding position. 
         [0040]    The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.