US 12,109,657 B2
Systems and methods for controlling drive roll contact force in welding-type systems
Richard M. Hutchison, Iola, WI (US); Todd Gerald Batzler, Hortonville, WI (US); and Dennis Roland Sigl, Greenville, WI (US)
Assigned to Illinois Tool Works Inc., Glenview, IL (US)
Filed by Illinois Tool Works Inc., Glenview, IL (US)
Filed on Jan. 7, 2020, as Appl. No. 16/736,516.
Claims priority of provisional application 62/798,598, filed on Jan. 30, 2019.
Prior Publication US 2020/0238421 A1, Jul. 30, 2020
Int. Cl. B23K 9/12 (2006.01); B23K 9/095 (2006.01); B23K 9/133 (2006.01)
CPC B23K 9/125 (2013.01) [B23K 9/0956 (2013.01); B23K 9/1333 (2013.01); B23K 9/1336 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A wire feeder for feeding an electrode wire from a wire source in a welding system, the wire feeder comprising:
a motor;
one or more drive rolls driven by the motor to advance an electrode wire by contact force, wherein the one or more drive rolls provide contact force through contact with the wire, and wherein a first drive roll of the one or more drive rolls includes a first contact area and a second contact area, the first contact area to make contact with the wire when the first drive roll is in a first position within the wire feeder, and the second contact area to make contact with the wire when the first drive roll is in a second position within the wire feeder; and
one or more interfaces to receive information from or provide information to a controller, the controller to:
receive a feedback signal corresponding to the contact force on the wire from the one or more drive rolls based on a position of the one or more drive rolls;
compare the contact force to a range of threshold contact force values; and
provide an alert via the one or more interfaces in response to the contact force falling outside the range of threshold contact force values.