Patent Description:
Implementation of automated processes in a welding workflow has a number of advantages. In particular, automation has the potential to improve the efficiency of various processes, including welding wire loading and feeding. Despite the advantages of automation, integration of standard welding wire spools with automated processes presents a number of challenges.

In particular, automated processes impose certain requirements on the weight of the spool. For example, the total weight of the spool that is loaded with wire must be above a certain minimum threshold in order to integrate with an automated wire feeder. Further, automated wire feeders are designed to work with standard spool dimensions that are defined by the American Welding Society ("AWS"). The requirements of using standard dimensioned spools coupled with the weight thresholds presents a challenge for implementation of automated processes with a broad range of wire types.

With many types of commonly used wires, industry standard dimensioned spools need to be filled with an amount of wire that extends to the edges of the spools' flanges in order to meet these weight thresholds. This is particularly true when utilizing lighter density (flux core) wires. The wire loaded onto the spool needs to be tied off at an opening located on the flange of an industry standard spool. When spools are filled with an amount of wire that extends to the edges of the spool's flanges, this opening is covered up by the wire. As a result, the automated wire hooking device may be unable to access the openings on the flange that are needed to tie off the wire.

There exists a need for an improved welding wire spool capable of integration with automated processes with a broad range of welding wire types and weights.

<CIT> discloses a spool provided with one or more clamps to sever a wire from the full spool and grip it at the commencement of winding on the empty spool.

According to an aspect of the invention, there is provided a welding wire spool as defined in the appended claims. According to a further aspect of the invention, there is provided a method for welding wire loading and feeding as defined in the appended claims.

The following is a description of the examples depicted in the accompanying drawings. The figures are not necessarily to scale, and certain features and certain views of the figures may be exaggerated in scale or in schematic for clarity or conciseness.

The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the figures. It should be understood that the claims are not limited to the arrangements and instrumentality shown in the figures. Furthermore, the appearance shown in the figures is one of many ornamental appearances that can be employed to achieve the stated functions of the apparatus.

As illustrated in <FIG>, a welding wire spool <NUM> comprises a drum <NUM> comprising an outer drum perimeter that extends between a first flange <NUM> and a second flange <NUM>. The drum <NUM> may comprise a drum opening <NUM> that extends through the thickness of the drum perimeter. Each flange <NUM>, <NUM> has an outer perimeter. The outer perimeter of the first and second flanges <NUM>, <NUM> is greater than the outer drum perimeter of the drum <NUM>. Each flange may have a flange opening that extends through the thickness of the flange. The first flange <NUM> comprises a flange opening <NUM> that extends through the thickness of the first flange <NUM>. A tab may be located along the outer perimeter of one or both of the flanges A tab <NUM> is located along the outer perimeter of the first flange <NUM> at an attachment area <NUM>. The tab <NUM> comprises a tab opening <NUM> that extends through the thickness of the tab <NUM>. A wire may be loaded onto the welding wire spool <NUM> and a length of wire may be passed through one or more of the openings (e.g., a length of wire may be passed through the tab opening <NUM> and "hooked" by bending a length of the wire so as to secure its position and limit unravelling of the wire from around the spool).

Similarly, as illustrated in <FIG>, a welding wire spool <NUM> comprises a drum <NUM> comprising an outer drum perimeter that extends between a first flange <NUM> and a second flange <NUM>. The drum <NUM> may comprise a drum opening <NUM> that extends through the thickness of the drum perimeter. Each flange <NUM>, <NUM> has an outer perimeter. The outer perimeter of the first and second flanges <NUM>, <NUM> is greater than the outer drum perimeter of the drum <NUM>. Each flange may have a flange opening that extends through the thickness of the flange. The first flange <NUM> comprises a flange opening <NUM> that extends through the thickness of the first flange <NUM>. A tab may be located along the outer perimeter of one or both of the flanges. A tab <NUM> is located along the outer perimeter of the first flange <NUM> at an attachment area, which comprises a relief line <NUM>. The tab <NUM> comprises a tab opening <NUM> that extends through the thickness of the tab <NUM>. A wire may be loaded onto the welding wire spool <NUM> and a length of wire may be passed through one or more of the openings (e.g., a length of wire may be passed through the tab opening <NUM> and "hooked" by bending a length of the wire so as to secure its position and limit unravelling of the wire from around the spool).

It may be advantageous to vary the relative locations of the tab, the flange opening, and the drum opening. For example, as illustrated in <FIG>, flange opening <NUM> may be located on first flange <NUM> directly below tab opening <NUM>. Further, as illustrated in <FIG>, drum opening <NUM> may be located along a radial axis that bisects flange opening <NUM>. Aligning one or more of the openings (e.g., aligning the tab opening <NUM> and the drum opening <NUM>) may provide advantages for automated systems so that a wire can be fed through one or more of the openings in an appropriate position. In another embodiment, as illustrated in <FIG>, flange opening <NUM> may be located in a position along first flange <NUM> that is not along a radial axis that bisects the drum opening <NUM>. In other aspects of the present disclosure, relative locations of the tab, flange opening, and drum opening may be varied along the flange and drum.

The tab opening <NUM>, <NUM> may be elliptical. In other embodiments of the present disclosure, the tab opening may comprise other shapes and sizes. For example, the tab opening may be circular, rectangular, trapezoidal, or semicircular. The shape and size of the tab may be varied depending on the type and size of the attachment area that is employed.

It may also be advantageous to vary the shape or size of the flange opening. The flange opening <NUM>, <NUM> may be circular and have a diameter that is smaller than the width of the tab opening <NUM>, <NUM>. In other embodiments of the present disclosure, the shape or size of the flange opening may be changed. Various factors - such as the size, shape, and weight of the wire that will be loaded onto the spool - may dictate what size flange opening is desirable. For example, the flange opening may be elliptical, rectangular, trapezoidal, or semicircular.

It may also be advantageous to vary the shape or size of the drum opening. The drum opening <NUM>, <NUM> may be trapezoidal. In other embodiments of the present disclosure, the shape or size of the drum opening may be changed. Various factors - such as the size, shape, and weight of the wire that will be loaded onto the spool - may dictate what size drum opening is desirable. For example, the drum opening may be circular, elliptical, rectangular, or semicircular.

In certain embodiments, the shape or size of the drum and the flanges can be varied. For example, it may be advantageous to adjust the diameter and thickness of both the drum and flanges depending on the type, thickness, and weight of the wire that is intended to be loaded onto the spool. It may also be advantageous to adjust the sizes of the drum and flanges depending on the intended tools that the spool will be implemented with. For example, different drum and flange sizes may be desirable depending on the type of spooler and the type of wire feeder that will be employed with the spool.

The welding wire spool may be made of any suitable material depending on the desired use of the spool. For example, the spool may be manufactured from plastics, steel, or fiberboard. In certain embodiments, the tab may be made from the same material as the other components of the welding wire spool. In other embodiments, the tab may be made of a different material as the other components of the welding wire spool.

In accordance with the invention, the tab is frangibly attached to one or both of the flanges. Depending on the desired application, various methodologies may be employed for the frangible attachment of the tab. For example, as illustrated in <FIG>, the tab <NUM> may be frangibly attached to the first flange <NUM> through an attachment area that comprises a relief line <NUM>. The relief line may comprise an area cutout from the flange. Such a design allows the tab to be attached in a manner that is secure, but still removable when needed. The relief line may vary in thickness depending on the thickness of the flange and the shape and size of the tab. In another embodiment of the present disclosure, the attachment area may comprise perforations. The choice of methodology for attaching the frangible tab may depend on various factors, such as the material the spool is made of (e.g., plastic, steel, or fiberboard), the timing of when the tab needs to be broken away, the methodology by which the tab will be broken away (e.g., manual versus automated), and the desired strength of the frangible attachment.

According to another embodiment of the present disclosure, a method for welding wire loading and feeding may comprise loading a spool into a spooler, using the spooler to load wire onto the spool, hooking a length of wire through the tab opening, and unloading the spool from the spooler. The spool employed in this method may comprise the elements described in the various embodiments above, and illustrated in <FIG> and <FIG>. According to one embodiment, the method may further comprise breaking the tab that is frangibly attached to one or both of the flanges away from the spool after unloading the spool from the spooler.

According to another embodiment of the present disclosure, a method for welding wire loading and feeding may comprise loading a spool into a spooler, using the spooler to load wire onto the spool, hooking a length of wire through the tab opening, and unloading the spool from the spooler. The spool employed in this method may comprise the elements described in the various embodiments above, and illustrated in <FIG> and <FIG>. According to one embodiment, the method may further comprise loading the spool into a wire feeder after unloading the spool from the spooler. According to another embodiment, the method may further comprise breaking the tab that is frangibly attached to one or both of the flanges away from the spool after loading the spool into the wire feeder.

Claim 1:
A welding wire spool (<NUM>; <NUM>) comprising:
A drum (<NUM>; <NUM>) having an outer drum perimeter and extending between a first flange (<NUM>; <NUM>) and a second flange (<NUM>; <NUM>), wherein each flange has an outer perimeter; and
a tab (<NUM>; <NUM>) that is located along the perimeter of the first flange;
wherein the outer perimeter of each of the first and second flanges is greater than the outer drum perimeter;
wherein the first flange has a flange thickness and comprises a flange opening (<NUM>; <NUM>) that extends through the flange thickness; and
wherein the tab has a tab thickness and comprises a tab opening (<NUM>; <NUM>) that extends through the tab thickness,
characterised in that the tab (<NUM>; <NUM>) is frangibly attached to the first flange (<NUM>; <NUM>) at an attachment area (<NUM>; <NUM>) located along the perimeter of the first flange.