Patent Abstract:
A modular welding system which can switch between right-handed and left-handed wire feeders by use of the modular design and without having a duplicative dual feed system is disclosed. This aspect is applicable to robotic welding as well as boom-mounted welding operations.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and fully incorporates by reference, U.S. Provisional Patent Application Ser. No. 61/641,376 filed on 2 May 2012. 
    
    
     TECHNICAL FIELD 
     This invention relates to a modular welding system which can be used with both left-handed and right-handed wire drive motor assemblies. 
     BACKGROUND OF THE INVENTION 
     Welding, such as gas metal arc welding, requires a continuous feed of metal wire to the welding tip, torch, nozzle, or gun, for use in the welding process. Wire feeders generally include a reel stand for holding a reel of wire and a wire drive module that draws wire from the reel and supplies it to the welding tip. 
     Wire feeders are provided as single and double header wire feeders, and additionally are typically available in both bench and boom mounted versions. In addition to the wire feeder, a welding system generally also includes welding gun connections, inlet gas connector (if necessary) with associated torch connector as well as a user interface with various required and optional control systems and interconnections. The wire feeder is often secured to the welding unit. With a single header wire feeder, wire from the wire feeder reel stand is routed to the welding unit according to the location of the wire drive system, i.e., on the left-hand side or right-hand side depending on the location of the drive motor. In a dual header wire drive, both wire reels and wire drive motors are positioned on both sides of the welding unit. While this obviates the left-handedness or right-handedness of the unit, it effectively increases both the size and cost of the unit. 
     With single header wire feeders, one possible solution to switching from a right-handed drive motor to a left-handed drive motor would be to simply rotate the entire wire drive and any associated controllers. However, this solution is not ideal because of cable routing and physical workspace limitation issues; for example the user interface may be in a position where it cannot be adjusted. 
     With dual header wire feeders, this solution requires maintaining additional, if substantially identical, product lines, manufacturing additional components, and requiring additional overhead to warehouse and shelve these products. 
     Therefore, there is a recognized need for a reversible wire feeder that may be interchangeably configurable to be used with a left-handed or right-handed wire feeder. 
     There is therefore recognized a need in the art for a wire feed unit that may be configured to provide dual wire feeding in a small footprint, or may be configured to provide either single or dual wire feeding with a single unit. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is provided a modular welding system which includes at least the following: at least one controller module, each of the at least one controller modules comprising at least one gas inlet connector and at least one welding control cable connector; at least one user interface module operatively connected to the at least one controller module; at least one separable wire drive module positionable from a first position to a second position, each of the separable wire drive modules comprising a feed module, the wire drive module connected to and in operative communication with the at least one controller module such that repositioning the wire drive module from the first position to the second position maintains the at least the at least one gas inlet connector, the at least one welding control cable connector and optionally the at least one user interface connector, on the same plane; and at least one wire feed means, which in one embodiment is a reel stand for supporting a reel of wire and providing the wire to the wire feeder, while in another embodiment is a welding wire box through which welding wire exits through an opening in the box; wherein the wire drive module is configurable to feed wire in either a first position or a second position. 
     In one aspect of the invention, the at least one separable wire drive module is positionable from the first position to the second position by rotation of the wire drive module about a central longitudinal axis of the wire drive module which is parallel to a wire feed axis. 
     In another aspect of the invention, the at least one separable wire drive module is positionable from the first position to the second position by rotation of the wire drive module about a central vertical axis of the wire drive module which is normal to a wire feed axis. 
     In yet another aspect of the invention, the at least one wire drive module further includes first and second connectors for selectively engaging the controller module upon rotation of the wire drive module. 
     The invention is not limited to a single welding system, but includes systems which have two welding systems in which there is at least two controller modules, at least two separable wire drive modules, each module having one wire drive positionable from a first position to a second position, each of the separable wire drive modules including a feed module, the wire drive module connected to and in operative communication with at least one controller module (optionally two controller modules) such that repositioning the wire drive module from the first position to the second position maintains the position of at least some of the connectors affixed to the controller modules in the same plane or surface. 
     The invention also includes a method for changing a wire feeder in a welding system from at least one welding wire drive which is positioned on one side of the wire feeder to an opposed side of the wire feeder including the following steps (without regard to order): providing at least one modular wire feeder having a controller module, at least one separable and repositionable wire drive module having a wire feeder, at least one user interface module, and a wire reel stand, the controller module, the wire drive module and the user interface module in operative connectivity; removing the welding wire drive from one side of the at least one wire feeder module to the opposed side of the wire feeder without repositioning any of the operative connectivity; positioning the at least one wire reel stand to match one of the wire feeder modules; reattaching the wire drive module to the opposed side of the at least one wire feeder without repositioning any of the operative connectivity; and controllably feeding wire from a reel of welding wire on the at least one wire reel stand through the wire feeder. 
     The method also encompasses the step of providing at least two modular wire feeders and also where the step of providing at least two modular wire feeders includes a first wire feeder which is positioned in a right-hand arrangement and a second wire feeder which is positioned in a left-hand arrangement. 
     The step of selecting a first or second position for a modular wire feeder includes the use of a switch on the user interface module for interface with the first wire feeder or the second wire feeder, the employment of which selectively engages to control one of the first or second wire feeders. 
     In still another aspect of the invention, a modular welding system is disclosed for use with a wire feeder for left- or right-hand wire feed, which includes: a controller module comprising at least a power connector and a gas inlet at one end of the controller module; a user interface module operatively connected to the controller module, the user interface module positioned at an opposed end of the controller module; a separable and repositionable wire drive module operatively connected to the controller module, the wire drive module further including a positionable wire feeder; a means for using either a left-handed or right-hand wire drive module without repositioning of the user interface module or the controller module. As before, the separable wire drive module is positionable (a) from a first position to a second position by rotation of the wire drive module about a central longitudinal axis of the wire drive module which is parallel to a wire feed axis or (b) from a first position to a second position by rotation of the wire drive module about a central vertical axis of the wire drive module which is normal to a wire feed axis. 
     The modular welding system further optionally includes a means for detecting if the wire feeder is in a left-hand or right-hand arrangement. 
     These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein: 
         FIG. 1 a    is a front perspective view of a prior art right-handed welding wire feed system with spindle, associated wire drive system and user interface; 
         FIG. 1 b    is a side perspective view of a prior art four roll drive right-handed welding wire feed drive system; 
         FIG. 1 c    is a side perspective of a prior art two roll drive right-handed welding wire feed drive system; 
         FIG. 2  is an exploded view of a left-handed modular wire feeder; 
         FIG. 3  is an exploded view of a right-handed modular wire feeder similar to that illustrated in  FIG. 1 ; 
         FIG. 4  is a perspective view of a left-handed wire feed module shown in  FIG. 2 ; 
         FIG. 5  is a cutaway view of a wire drive module taken along line  5 - 5  in  FIG. 2 ; 
         FIG. 6A  is a side view of the wire drive module illustrated in  FIG. 3 ; 
         FIG. 6B  is a side view of the wire drive module of  FIG. 6A  with the feed cover removed; 
         FIG. 6C  is a side view of the wire drive module of  FIG. 6A  illustrating the drive shaft; 
         FIG. 7  is an exploded perspective view of the modular wire feeder illustrating plug-in capability; 
         FIG. 8  is an exploded perspective view of the wire feeder; 
         FIG. 9A  is a front plan view of multiple wire feeders in which the control modules are interposed between the wire drive modules positioned both above and below; 
         FIG. 9B  is a front plan view of multiple wire feeders in which the control modules are positioned below each wire drive modules; and 
         FIG. 10  is a plan view of a user control interface. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting same,  FIG. 1A  illustrates a prior art right-handed drive motor welding wire feed system  100  with welding wire spindle  102 , associated wire drive system  104  and user interface  106 . While a welding wire spindle is illustrated in the Figure, there is no need to limit the invention to the same, and welding wire feeding means would include welding wire sourced from a box. 
     As better illustrated in  FIGS. 1B &amp; 1C , wire drive systems are available with a two roll drive, see  FIG. 1C , and a four roll drive, see  FIG. 1B . As illustrated with this particular wire drive system  104 , the system includes at least one tensioner  108  to set the tension upon the welding wire and either a pair of drive rolls  110   a ,  110   b , better illustrated in  FIG. 1C  or two pairs of drive rolls,  112   a ,  112   b  and  114   a ,  114   b  better illustrated in  FIG. 1B . Fastening hub  116  is affixed to the protruding axle of the drive wheels for securing engagement. In an optional aspect of the invention, split wire guide  118  is positioned between the drive wheels for full welding wire support throughout the drive path. 
     As shown in  FIG. 2 , modular wire feeder  20  includes controller module (illustrated as positioned within base  22 , although the module could be positioned within modular wire feeder  26  or user interface module  24 ), user interface module  24 , wire drive module  26  with left-handed wire feeder  28  as well as welding wire reel stand  30  with spindle  32 . Appropriate modules are connected to one another, mechanically and/or electrically, providing communication therebetween, the electronic connection including wireless transmission. 
     As better illustrated in  FIG. 3 , controller module  22  includes power cable  34  and optionally, gas line  36  providing shielding gas for the welding operation. When appropriate, control module  22  includes interface  38  for connecting to and utilizing the shield gas and power, for example to a separate or integral welding unit. 
     User interface module  24  is operatively connected to controller module  22  by means of user interface cable  40 , recognizing that wireless connectivity is within the scope of this invention. User interface cable  40  receives input from user interface module  24  and electronically communicates appropriate information to control module  22 , which in turn, communicates appropriate information to wire drive module  26  or other components. Control module  22  communicates with user module  24  through interface cable  40 , providing power, gas flow information, or other data useful in the welding process. User interface module  24  optionally includes dials, displays, or other control or display elements as known in the art. 
     As illustrated in  FIG. 3 , wire drive module  26  is connected to controller module  22  by means of wire drive cable  42  which communicates information between controller module  22  and wire drive module  26 , the information including, but not limited to, the rate of wire transfer, size of wire, wire tension and other information. 
     As illustrated in more detail in  FIG. 4 , the basic configuration of wire drive module  26  includes housing  44  and wire feeder  28 . As illustrated in the figure, housing  44  is generally rectangular, having opposed top  46  and bottom  48  as well as opposed left  50  and right  52  sides. These designations are intended to be illustrative rather than limiting, and not intended to convey a specific arrangement or position of wire drive module  26 . As will become apparent from the following description and drawings, wire drive module  26  is positionable in several different arrangements. 
     As further shown in  FIGS. 4 &amp; 6A , wire feeder  28  includes wire receiving end  54  and wire exiting end  56 , often, but not necessarily, a circular aperture. Wire from the reel positioned onto spindle  32  of wire reel stand  30  is received in receiving end  54  of feeder  28 , straightened, and fed through the wire exiting end  56  at a rate communicated to wire drive module  26  by controller module  22  as set by the user at user-interface  24 . It should be noted that spindle  32  is positionable on either side of wire reel stand  30  as illustrated in a comparison of  FIG. 2  and  FIG. 3  illustrates. 
       FIG. 5  is a cutaway view showing the internal arrangement of wire drive module  26 . In this figure, housing  44  contains drive motor  58  that rotates drive shaft  60  by means of a series of gears, a worm gear, belt, or other configuration known in the art. Drive motor  58  is shown as being perpendicular to drive shaft  60 , although it should be recognized that the drive motor is be of any arrangement including parallel, perpendicular, or angled relative to drive shaft  60 . As illustrated, the drive shaft extends between opposed left  50  and right  52  sides of housing  44 . 
     In the arrangement shown in  FIG. 4 , wire feeder  28  has been positioned on the left  50  side of housing  50 . The wire feeder as shown includes feeder cover  62 , drive shaft engagement gear  64 , drive rolls  66 A-B, and wire feed path  68  through which wire is capable of being fed. 
       FIGS. 6A-C  show a side view of wire drive module  26  and wire feed module  28  in various stages of disassembly. In  FIG. 6A , wire feed module  28  is shown with cover  62  in place. Welding wire  68  enters feed module  28  at receiving end  54  and exits feed module  28  at wire exiting end  56 . 
     In  FIG. 6B , cover  62  has been removed, showing drive system  70  and welding wire  68  passing through the system. Drive system  70  includes drive shaft engagement gear  64  that is coupled to drive shaft  60 . As shown, drive shaft  60  includes a keyed or shaped end that enables rotational movement to be transmitted to drive shaft engagement gear  64 . In  FIG. 5B , drive shaft  60  is shown with a triangular cross-section, however it will be apparent that a variety of arrangements including square, hexagonal, keyed, or other arrangements are contemplated. 
     As illustrated in the figure, drive system  70  include feed plate  72  onto which a number of drive rolls  66 A-D are rotatably mounted. These drive rolls serve various purposes, including straightening, feeding, aligning, and regulating wire  68  as it is fed through feed module  28 . The drive rolls are driven by the drive shaft engagement gear  64 , and therefore feeds or retracts the wire as required. 
       FIG. 6C  shows a side view of wire drive module  26  with wire feeder  28  removed. Visible in this view is drive shaft  60 . As illustrated in this figure, drive shaft  60  is accessible from either side of drive module  26 . This allows wire feeder  28  to be installed to either left-  50  or right-hand side  52  of drive module  26 . Drive shaft  60  engages drive shaft engagement gear  64  by protruding slightly from the sides of the housing or drive shaft engagement gear  64  extends into housing  44  to engage drive shaft  60 . Alternatively, wire drive module  26  is manufactured as described above and housing  44  is constructed so that only one end of drive shaft  60  is exposed, thereby preventing contamination of the internal components of drive shaft  60 . 
     It will be apparent that the above-described apparatus allows for a modular wire drive system. The wire drive system allows for a user to select either a left- or right-hand feed and change from one system to another without additional cost, parts, or product lines. 
     As illustrated in  FIG. 7 , wire drive module  26  is rotatable (either by fixed increments or by free rotation), but preferably at least by 180° about an axis A to present either a left- or right-handed wire feed. Wire drive module  26  is connected to controller module  22  through connector  74 , such as a 19-pin control cable connection (or other control cable with different numbers of pins or orientations or communication protocol dictated by other electrical considerations), or by means of a cable (better illustrated in  FIG. 1 ) between wire drive module  26  and controller module  22 . If a direct connection is preferred, connector  74  is keyed so as to indicate to the controller module whether wire drive module  26  is in a left- or right-hand arrangement. One implementation of this arrangement includes connector  74  offset from the center as shown by ports  76 A,  76 B in wire drive controller module  22  depending on the arrangement. For example, in a left-hand feed arrangement connector  74  engages first port  76 A; and in a right-hand feed arrangement connector  74  engages second port  76 B. The engagement of first or second ports  76 A,  76 B communicate pertinent information to wire drive controller module  22 , e.g., the arrangement of the wire drive module. 
     In this aspect, when wire drive module  26  is switched between the left- and right-hand feed arrangements, wire feeder  28  will generally not have cover  28  positioned thereupon, but will have a more mirror image front and rear components to the housing so that wire properly enters receiving end  54  and exits wire exiting end  56  of the wire feeder. As illustrated, wire feeder  28  is rotatable about drive axis  60  allowing receiving end  54  of the wire feeder to be positioned toward wire reel stand  30 . 
     As illustrated in  FIG. 8 , wire drive module  26  is rotatable about an axis B-B. Positioning wire feeder  28  on either the left- or right-hand side without requiring adjustment of the wire feeder. According to this arrangement, wire drive module  26  includes cable  78  extending from the rear of module  26  that connects to controller module  22 . When wire drive module  26  is rotated about axis B-B, cable  78  does not need to be adjusted to accommodate this adjustment. 
     As shown in  FIGS. 9A &amp; 9B , multiple modular wire feeders  20 ′,  20 ″ are illustrated adjacent to one another, thereby allowing two welders to be operated simultaneously. Unlike current generation wire feeders, these are stackable on top of one another as shown or positionable in a side-by-side arrangement. The feeders  20 ′,  20 ″ are positioned with corresponding control modules  22 ′,  22 ″ adjacent to one another ( FIG. 9A ) or separated from one another ( FIG. 9B ) as desired. 
     An advantage when using multiple modular wire feeders  20 ′,  20 ″ is the ability to use dual-mode user interface module  80  for controlling two (or more) feeders as shown in  FIG. 10 . As illustrated in the figure, dual-mode user interface module  80  is provided with selector  82  which embodies various forms, e.g., a switch, button, lever, or other device and indicator lights  84 A,  84 B indicating whether the first- or second-feeder  20 ′,  20 ″ is being controlled. Additional remaining controls  86 , include controls for voltage, wire feed speed, gas flow rate, and other parameters are substantially identical to those provided for a single feed control module  24  ( FIGS. 2 &amp; 3 ). An operator selects the desired parameters for first wire feeder  20 ′, then press the selector  82  and control the parameters for second wire feeder  20 ″. Indicator lights  84 A,  84 B are provided to indicate to the user which system is being controlled. 
     Also disclosed is a novel method of using a modular wire feeder as shown in the appropriate figures. According to this method modular wire feeder  20  is provided having control module  22 , user interface module  24 , wire drive module  26  having a wire feeder  28 , and wire reel stand  30  having spindle  32 . Either a left- or right-hand wire feed arrangement is selected according to the needs of the user by repositioning spindle  32  to the appropriate side of wire reel stand  30 . Wire reel stand  30  is arranged so that spindle  32  is arranged in a left- or right-hand feed arrangement and wire drive module  26  is positioned in the same arrangement. 
     According to one option in the method, wire feeder  28  is removed from one side of wire drive module  26  and reaffixed to its opposed side. Further according to this embodiment, wire drive module  26  includes drive shaft  60  driven by drive motor  58 . Drive shaft  60  extends between the left and right sides of wire drive module  26  and wire feeder  28  engages drive shaft  60  from the appropriate side. Drive shaft  60  preferably includes a shaped end, such as a hexagonal, triangular, keyed or other shape for engaging drive shaft engagement gear  64  of wire feeder  28 . It is however, recognized that a shaped end is not an absolute requirement of the invention and other methodologies of fixing the shaft are within the scope of the invention, e.g., use of a set screw or a “C-shaped” shaft. 
     According to another option in the method, wire feeder  28  is reversible, rotatable, or reconfigurable (for example by switching input and output bearings). Wire drive module  26  is rotatable about an axis A-A, allowing the feeder to be positioned upon either side of control module  22 . With this option, wire drive module  26  includes connector  74  and ports  76 A,  76 B on control module  22 . When the wire feed module is in a first configuration (e.g., left-hand feed), connector  74  engages a first port  76 A while in a second configuration connector  74  engages second port  76 B. Control module  22  optionally automatically detects which port  76 A or  76 B is engaged and therefore will know whether wire drive module  26  is in the left- or right-hand feed arrangement. 
     According to yet another option in the method, wire drive module  26  is rotatable about an axis B-B. Wire drive module  26  includes cable  78  positioned in one instance on the back of wire drive module  26  so that the relative position of the cable  78 —module  26  interface is not changed when drive module  26  is rotated. 
     When multiple modular wire feeders  20 ′,  20 ″ are employed, for example in a stacked or side-by-side arrangement, the modules are stackable so that either a left- or right-handed wire feeder is positioned above or below. Once wire feeder  20  (or feeders  20 ′,  20 ″) has been selected and arranged, control module  22  is connected to user interface module  24 . This connection may be by a direct connection, cable connection, or wireless connection. User interface module  80  typically includes means for controlling two or more wire feeder units  20 ′,  20 ″. User interface module  80  includes selector switch  82 , two or more indicator lights  84 A,  84 B, and controls  86  similar to those for user interface module  24  controlling a single feeder. In this arrangement, the method for operating multiple wire control modules includes the step of engaging selector  82  to select wire control module  20 ′, configuring wire control module  20 ′, and selecting another wire control module  20 ″ by means of selector  82 . This allows for multiple wire feed modules to be provided and controlled from a single user interface module. 
     The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Technology Classification (CPC): 1