Patent Application
20230331512
The present invention relates to a kink prevention jig and a pail pack.
In recent years, automation and robotization of welding are progressing. Therefore, there is a large demand for lengthening a welding wire such as a solid wire for MAG welding and a flux-cored wire for MAG welding, and use of a pail pack containing a laminated welding wire is increasing. However, with the pail pack, when welding is continuously performed, the welding wire is twisted near an outlet of the pail pack, causing a kink and stopping withdrawal of the welding wire. Since the occurrence of the kink causes a decrease in an operation rate in robot welding or the like, it is required to prevent the kink.
Patent Literature 1 describes a pail pack in which an inner cylinder and an outer cylinder are coaxially disposed on a bottom plate of the pail pack, a welding wire laminated in a coil shape is accommodated between the inner cylinder and the outer cylinder, and a pressing member is placed on the coil-shaped welding wire. In the pail pack, the pressing member prevents the welding wire from being entangled and knotted when the welding wire is drawn out.
Patent Literature 1: Japanese Patent No. 5198424
However, even when the pail pack described in Patent Literature 1 is used, a kink may still occur, and a further kink prevention measure is required.
The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a kink prevention jig and a pail pack with which an occurrence of a kink can be prevented when a wire is drawn out.
The above object of the present invention is achieved by the following configuration (1) related to a kink prevention jig.
(1) A kink prevention jig for a pail pack,
According to this configuration, when the kink prevention jig is used for the pail pack, an occurrence of a kink can be prevented when the wire is drawn out.
A preferred embodiment of the kink prevention jig according to the present invention relates to the following (2) to (4).
(2) The kink prevention jig according to (1), in which a top portion of the wire abutting portion is located at a height greater than H1 + ½ × (H2-H1), where H1 is a height of the housing and H2 is a height of the draw-out opening.
According to this configuration, since a space through which the wire passes is narrowed and the wire is guided to the vicinity of the draw-out opening, the occurrence of the kink can be prevented more reliably.
(3) The kink prevention jig according to (1) or (2),
According to this configuration, the inner cylinder in the pail pack and the kink prevention jig can be connected, and the kink prevention jig can be disposed on the inner cylinder.
(4) The kink prevention jig according to any one of (1) to (3), in which the wire abutting portion is formed in a substantially conical shape.
According to this configuration, the wire can be smoothly guided toward the draw-out opening for the wire.
The above object of the present invention can be achieved by the following configuration (5) related to a pail pack.
(5) A pail pack including the kink prevention jig according to any one of (1) to (4).
According to this configuration, an occurrence of a kink can be prevented when the wire is drawn out from the pail pack.
A preferred embodiment of a pail pack according to the present invention relates to the following (6) and (7).
(6) The pail pack according to (5), further including:
a pressing plate configured to press the laminated wire downward, in which the pail pack is configured such that the laminated wire is drawn out in an interior drawer manner.
According to this configuration, an occurrence of a kink in an interior drawer manner pail pack can be prevented.
(7) The pail pack according to (5) or (6), further including:
According to this configuration, the wire passes through a space between the lid body and the substantially conical kink prevention jig, and thus the space through which the wire passes is narrowed, and the occurrence of the kink can be effectively prevented.
According to the present invention, it is possible to provide a kink prevention jig and a pail pack with which an occurrence of a kink can be prevented when a wire is drawn out.
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Hereinafter, a kink prevention jig according to an embodiment of the present invention will be described in detail with reference to the drawings. As shown in
A diameter D2 of a bottom surface 13 of the conical portion 12 is larger than a diameter D1 of the cylindrical portion 11. The bottom surface 13 of the conical portion 12 includes flange--shaped outward extending portions 14 extending from an upper outer peripheral portion of the cylindrical portion 11 in an outer radial direction. A length L of the outward extending portion 14 in a radial direction, the diameter D1, the diameter D2, and a height of the conical portion 12 are appropriately set according to a size of the pail pack 30 to be used. In the present embodiment, the outward extending portion 14 extends from the cylindrical portion 11 toward an outer peripheral edge 15 in a horizontal direction, but may extend obliquely downward or obliquely upward from the cylindrical portion 11 toward the outer peripheral edge 15.
In the kink prevention jig 10, the outer peripheral edges 15 of the bottom surface 13 of the conical portion 12 and a conical surface 16 of the conical portion 12, which is a wire abutting portion, abut against a welding wire W to be drawn out, thereby preventing a kink from occurring in the wire W. A shape of a generatrix forming the conical surface 16 may be straight, concave, convex, or curved, and is preferably straight or convex.
The cylindrical portion 11 and the conical portion 12 of the kink prevention jig 10 may be integrally molded solidly or hollowly, for example, with a resin or metal, or may be a frame member formed by combining a plurality of generatrix forming the outer peripheral edge 15 of the bottom surface 13 of the conical portion 12 and the conical surface 16 of the conical portion 12 with wires or the like.
The cylindrical portion 11 may be a connecting portion that engages with the inner cylinder 34 (see
As shown in
As shown in
The lid body 32 is formed in a substantially truncated cone shape with an outer diameter gradually decreasing upward, and a cap 38 including a draw-out opening 37 from which the wire W is drawn out is fixed to a top portion 36 of the lid body 32. The housing 31 forms an accommodation space S1 for accommodating the laminated wire 50 therein. The lid body 32 forms a passage space S3 with the kink prevention jig 10, as will be described later. In the present embodiment, the term “upward” means a vertically upward direction along an axial direction of the outer cylinder portion 35 of the pail pack 30, and the term “downward” described later means a vertically downward direction along the axial direction of the outer cylinder portion 35 of the pail pack 30.
A wire pressing plate 40 is placed on the laminated wire 50, and the laminated wire 50 is pressed downward by a weight of the wire pressing plate 40. An outer diameter of the wire pressing plate 40 is slightly smaller than an inner diameter of the outer cylinder portion 35, and the wire pressing plate 40 is movable inside the outer cylinder portion 35 in the axial direction of the outer cylinder portion 35.
On the other hand, an inner diameter of the wire pressing plate 40 is larger than an outer diameter of the inner cylinder 34, and a gap C1 for drawing out the welding wire W is provided between an inner peripheral end edge 40a of the wire pressing plate 40 and an outer peripheral surface of the inner cylinder 34. Since a size of the gap C1 is set to be larger than a diameter of the welding wire W, the welding wire W can be drawn out from between the wire pressing plate 40 and the inner cylinder 34. That is, the pail pack 30 shown in
As shown in
A height H3 from the bottom plate portion 33 of the housing 31 to a top portion 17 of the conical surface 16, which is a wire abutting portion, is preferably greater than H1 + ½ × (H2 - H1), where H1 is a height of the housing 31 and H2 is a height from the bottom plate portion 33 of the housing 31 to the draw-out opening 37. That is, H3 > H1 + ½ × (H2 - H1) is preferred, H3 > H1 + ⅝ × (H2 - H1) is more preferred, H3 > H1 + ¾ × (H2 - H1) is further preferred, and H3 > H1 + ⅞ × (H2 - H1) is particularly preferred. As the height H3 from the bottom plate portion 33 of the housing 31 to the top portion 17 of the conical surface 16 increases, the welding wire W can be guided along the jig to the vicinity of the draw-out opening 37, and thus the kink prevention effect is further enhanced.
Next, an operation of the pail pack 30 including the kink prevention jig 10 will be described. As shown in
The wire pressing plate 40 is moved downward as the welding wire W is drawn out and the height of the laminated wire 50 decreases.
The welding wire W drawn out from the laminated wire 50 passes through the gap C2 between the outer peripheral edge 15 of the conical portion 12 and the inner peripheral surface of the outer cylinder portion 35 of the pail pack 30 to come into sliding contact with the outer peripheral edge 15 of the conical portion 12, then is drawn out upward while being moved in a circumferential direction along the conical surface 16, and is led out to the passage space S3.
As a result of intensive studies by the present inventors, it has been found that, in the “interior drawer manner” pail pack 30 as shown in the present embodiment, twisting is accumulated in the welding wire W as the welding wire W is drawn out for a long time, so that the welding wire W laminated in a ring shape may rise upward so as to pass over the inner cylinder 34 while being in a ring shape. At this time, it was confirmed that, in the case of a related-art pail pack without a kink prevention jig, the ring-shaped welding wire W climbs over the inner cylinder 34 to cause a kink. On the other hand, in the kink prevention jig 10 according to the present embodiment, since the bottom surface 13 of the conical portion 12 blocks an upper side of the inner cylinder 34, even when the welding wire W goes around a side portion of the wire pressing plate 40 and comes out above the wire pressing plate 40 while being in a ring shape, the welding wire W coming out upward from the wire pressing plate 40 can be prevented from climbing over the inner cylinder 34 because the welding wire W abuts against the bottom surface 13 (outward extending portion 14) of the conical portion 12.
When twisting is further imparted to the welding wire W, the welding wire W is about to climb over the outward extending portion 14 to form a kink, but in the present embodiment, the conical surface 16 of the kink prevention jig 10 prevents the occurrence of the kink. Here, the inventors have found that when the welding wire W is about to form a kink above the inner cylinder 34, the welding wire W is twisted such that the welding wire W is directed toward a central axis of the outer cylinder portion 35 of the pail pack. Therefore, the kink prevention jig 10 is provided with the conical surface 16 that abuts against the welding wire W such that the welding wire W cannot form a kink. In the present embodiment, the space in the lid body 32 is preferably filled by 50% or more, more preferably 60% or more, still more preferably 70% or more, and particularly preferably 80% or more by the kink prevention jig 10.
The height H3 from the bottom plate portion 33 of the housing 31 to the top portion 17 of the conical surface 16, which is a wire abutting portion, is greater than H1 + (H2 - H1) × ½, where H1 is the height of the housing 31 and H2 is the height from the bottom plate portion 33 of the housing 31 to the draw-out opening 37 for the welding wire W of the lid body 32. Therefore, the passage space S3 formed inside the lid body 32 is narrowed by the kink prevention jig 10. Since the passage space S3 is a narrow space having a substantially annular shape, even when the welding wire W is twisted in the passage space S3, formation of a kink can be prevented because the welding wire W interferes with the conical surface 16 of the conical portion 12, which is a wire abutting portion, and a free movement of the welding wire W is restricted. Then, the welding wire W passes through the draw-out opening 37 of the cap 38 and is led out to the outside of the pail pack 30.
In this way, a movement of the welding wire W drawn out from the laminated wire 50 is restricted at an upstream portion viewed from the laminated wire 50 by the gap C1 between the inner peripheral end edge 40a of the wire pressing plate 40 and the outer peripheral surface of the inner cylinder 34. The movement of the welding wire W is restricted at an intermediate portion viewed from the laminated wire 50 at the gap C2 by the outer peripheral edge 15 of the conical portion 12 which is in sliding contact with the welding wire W. Further, the movement of the welding wire W is restricted at a downstream portion viewed from the laminated wire 50 by the draw-out opening 37 of the cap 38. Since the free movement of the welding wire W is restricted at three positions of the upstream portion, the intermediate portion, and the downstream portion, and an occurrence of slack is effectively prevented, a kink is prevented from being formed in the welding wire W.
In the present embodiment, when the size of the gap C2 between the outer peripheral edge 15 of the conical portion 12 and the inner peripheral surface of the outer cylinder portion 35 of the pail pack 30 is equal to or less than 0.10 times as large as the inner diameter D3 of the outer cylinder portion 35, the effect of restricting the laminated wire 50 by the gap C2 can be further improved. As a result, the occurrence of slack in the welding wire W is effectively prevented, and the effect of preventing a kink from being formed in the welding wire W can be enhanced.
On the other hand, when the size of the gap C2 is equal to or more than 0.05 times as large as the inner diameter D3, it is possible to prevent the gap C2 from becoming too narrow and to secure wire feedability.
Therefore, the size of the gap C2 is preferably equal to or more than 0.05 times, and preferably equal to or less than 0.10 times as large as the inner diameter D3 of the outer cylinder portion 35.
In order to set a relationship between the size of the gap C2 and the inner diameter D3 of the outer cylinder portion 35 within the above range, for example, the diameter D2 of the outer peripheral edge 15 of the conical portion 12 in the kink prevention jig 10 may be set to be equal to or more than 0.80 times and equal to or less than 0.90 times as large as the inner diameter D3 of the outer cylinder portion 35.
As a result of intensive studies, the present inventors have found that there is a case where excessive twisting is accumulated in the welding wire W inside the pail pack 30 due to long-time welding, and in this case, the welding wire W is likely to cause a kink particularly above the cylindrical portion 11. Therefore, the kink prevention jig 10 described above eliminates the space required for the welding wire W to form a kink, thereby preventing the kink. That is, the kink prevention jig 10 acts as a wall to restrict the movement of the welding wire W, thereby preventing the kink.
A free movable weight (not shown) may be disposed above the wire pressing plate 40. The free movable weight has, for example, a spherical shape, and a through hole through which the welding wire W is inserted is formed in the free movable weight. A diameter of the free movable weight is set to be larger than that of the gap C1 between the inner peripheral end edge 40a of the wire pressing plate 40 and the inner cylinder 34, and an inner diameter of the through hole is set to be larger than that of the outer diameter of the welding wire W. When the welding wire W is drawn out from the laminated wire 50, the free movable weight revolves along the outer peripheral surface of the inner cylinder 34 while being in contact with the wire pressing plate 40 and the inner cylinder 34 above the gap C1. At this time, slack of the welding wire W is prevented by the free movable weight, thereby preventing the occurrence of a kink.
In the pail pack 30 including the kink prevention jig 10A according to the modification shown in
As shown in
The lid body 32 is formed in a substantially truncated cone shape with an outer diameter gradually decreasing upward, and the cap 38 having a draw-out opening 37 from which the welding wire W is drawn out is fixed to the top portion 36 of the lid body 32. That is, the housing 31 forms the accommodation space S1 for accommodating the laminated wire 50 therein, and the lid body 32 forms the passage space S3 having a substantially truncated cone shape therein.
The annular wire pressing plate 40 is placed on the laminated wire 50, and the laminated wire 50 is pressed downward by a weight of the wire pressing plate 40. An outer diameter of the wire pressing plate 40 is smaller than an inner diameter of the outer cylinder portion 35, and the gap C1 for drawing out the welding wire W is provided between an outer peripheral end edge 40b of the wire pressing plate 40 and an inner peripheral surface of the outer cylinder portion 35. A size of the gap C1 is set to be larger than an outer diameter of the welding wire W.
Similar to the first embodiment, the kink prevention jig 10 is attached to the pail pack 30 by engaging the cylindrical portion 11 with the inner cylinder 34 of the pail pack 30. Accordingly, a substantially truncated conical internal space formed by the lid body 32 is narrowed by the conical portion 12, and a space through which the welding wire W drawn out from the laminated wire 50 can pass is the passage space S3 which is a portion obtained by subtracting the volume S2 of the conical portion 12 from the substantially truncated conical internal space formed inside the lid body 32. The diameter D2 of the bottom surface 13 of the conical portion 12 is smaller than an inner diameter of the outer cylinder portion 35, and the gap C2 is provided between the outer peripheral edge 15 of the conical portion 12 and the inner peripheral surface of the outer cylinder portion 35 of the pail pack 30.
Similarly, in the present embodiment, the height H3 of the top portion 17 of the conical surface 16, which is a wire abutting portion, is set to be greater than H1 + (H2 — H1) × ½, where H1 is the height of the housing 31 and H2 is the height of the draw-out opening 37 for the welding wire W of the lid body 32.
The welding wire W drawn out from one end of the laminated wire 50 on an outer diameter side (that is, the outer cylinder portion 35 side) is drawn out upward from the gap C1 between the outer peripheral end edge 40b of the wire pressing plate 40 and the inner peripheral surface of the outer cylinder portion 35, and is further led out to the outside of the pail pack 30 from the draw-out opening 37 of the cap 38 provided in the lid body 32.
The wire pressing plate 40 is moved downward as the welding wire W is drawn out and the height of the laminated wire 50 decreases.
The welding wire W drawn out from the laminated wire 50 and drawn out to the accommodation space S1 passes through the gap C2 between the outer peripheral edge 15 of the conical portion 12 and the inner peripheral surface of the outer cylinder portion 35 of the pail pack 30 to come into sliding contact with the outer peripheral edge 15 of the conical portion 12, then is drawn out upward while being moved in a circumferential direction along the outer peripheral edge 15, and is led out to the passage space S3.
The height H3 from the bottom plate portion 33 of the housing 31 to the top portion 17 of the conical surface 16, which is a wire abutting portion, is greater than H1 + (H2 — H1) × ½, where H1 is the height of the housing 31 and H2 is the height from the bottom plate portion 33 of the housing 31 to the draw-out opening 37 for the welding wire W of the lid body 32. Therefore, the passage space S3 formed inside the lid body 32 is narrowed by the kink prevention jig 10. Since the passage space S3 is a substantially annular narrow space, even when the welding wire W is about to be twisted and entangled in the passage space S3, entanglement can be prevented because the welding wire W interferes with the conical surface 16 of the conical portion 12, which is a wire abutting portion, and a free movement of the welding wire W is restricted. Then, the welding wire W passes through the draw-out opening 37 of the cap 38 and is led out to the outside of the pail pack 30.
In this way, a movement of the welding wire W drawn out from the laminated wire 50 is restricted at an upstream portion viewed from the laminated wire 50 by the gap C1 between the outer peripheral end edge 40b of the wire pressing plate 40 and the inner peripheral surface of the outer cylinder portion 35, the movement of the welding wire W is restricted at an intermediate portion viewed from the laminated wire 50 by the gap C2 by the outer peripheral edge 15 of the conical portion 12 which is in sliding contact with the welding wire W, and the movement of the welding wire W is restricted at a downstream portion viewed from the laminated wire 50 by the draw-out opening 37 of the cap 38. Since the free movement of the welding wire W is restricted at three positions of the upstream portion, the intermediate portion, and the downstream portion, and an occurrence of slack is effectively prevented, the welding wire W is prevented from being entangled as in the first embodiment.
Similarly, in the second embodiment, a size of the gap C2 between the outer peripheral edge 15 of the conical portion 12 and the inner peripheral surface of the outer cylinder portion 35 of the pail pack 30 is preferably equal to or more than 0.05 times and preferably equal to or less than 0.10 times as large as the inner diameter D3 of the outer cylinder portion 35.
In order to set a relationship between the size of the gap C2 and the inner diameter D3 of the outer cylinder portion 35 within the above range, the diameter D2 of the outer peripheral edge 15 of the conical portion 12 in the kink prevention jig 10 may be set to be equal to or more than 0.80 times and equal to or less than 0.90 times as large as the inner diameter D3 of the outer cylinder portion 35.
In the pail pack 30 according to the third embodiment, the outward extending portion 14 of the conical portion 12 has a shape extending obliquely upward from the cylindrical portion 11 toward the outer peripheral edge 15. An angle β shown in
In this way, when the outward extending portion 14 of the conical portion 12 has a shape extending obliquely upward from the cylindrical portion 11 toward the outer peripheral edge 15, both an effect of preventing the wire W from floating up and an effect of improving wire feedability can be improved. In particular, when the angle β is 40° or less, the wire W can be prevented from floating up by the outward extending portion 14, and the wire feedability is improved. Therefore, the angle β is preferably 40° or less, more preferably 30° or less, and still more preferably 20° or less.
As described above, the angle β may be negative, that is, the outward extending portion 14 of the conical portion 12 may have a shape extending obliquely downward from the cylindrical portion 11 toward the outer peripheral edge 15. The angle β is preferably 0° or more in order to secure the wire feedability. The angle β is more preferably 0° or more and 10° or less for the reason that the kink prevention jig 10 can be easily manufactured.
Similar to the first embodiment, the lid body 32 of the pail pack 30 is formed in a substantially truncated cone shape with an outer diameter gradually decreasing upward, and the cap 38 including the draw-out opening 37 from which the wire W is drawn out is fixed to the top portion 36 of the lid body 32. A plastic--made pipe 41 is disposed on an inner surface side of the cap 38 with which the wire W comes into contact, and a wire lead-in opening 42 radially expanding toward the passage space S3 is formed in the pipe 41.
In this way, when the pipe 41 disposed on the cap 38 radially expands downward, i.e., toward the passage space S3, the wire W is easily led from the passage space S3, the wire is unlikely to be curled, and thus the feedability can be improved.
A material of the pipe 41 is preferably a material capable of preventing a wear and an occurrence of scrap metal due to sliding between the pipe 41 and the wire W, and is preferably, for example, plastic, or ceramic.
When the pipe 41 including the wire lead-in opening 42 is made of a material capable of preventing a wear or the like due to sliding with the wire W, the occurrence of scrap metal can be prevented, and thus an occurrence of feeding failure or the like due to accumulation of scrap metal can be prevented.
The present invention is not limited to the embodiments described above, and modifications, improvements, and the like can be made as appropriate.
For example, as a kink prevention jig 10C according to still another modification, as shown in
As shown in
Further, as kink prevention jigs 10E and 10F according to other modifications, as shown in
In this case, the outer peripheral edge of each disk 25 acts as a wire abutting portion that guides the welding wire W, and prevents the welding wire W from being entangled. In
Further, as a kink prevention jig 10G according to still further another modification, as shown in
Although various embodiments have been described above with reference to the drawings, it is needless to say that the present disclosure is not limited to such examples. It will be apparent to those skilled in the art that various alterations, modifications can be conceived within the scope of the claims, and it should be understood that they also belong to the technical scope of the present disclosure. Each component in the various embodiments described above may be combined arbitrarily in the range without deviating from the spirit of the invention.
The present application is based on a Japanese Patent Application (Patent Application No. 2020-151376) filed on Sep. 9, 2020, the contents of which are incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-151376 | Sep 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/032559 | 9/3/2021 | WO |
