Apparatus and method for feeding filler wire in a welding operation

In a welding system having a welding torch with a welding tip for welding a workpiece, a method of feeding filler wire comprising steps of:

• drawing the filler wire from a supply using a drive mechanism attached by a mounting arm to the welding torch, the mounting arm including a first bracket attached to the welding torch and an arced tube member attached the drive mechanism, the arced tube member in sliding engagement with the first bracket to vary the position of the drive mechanism and the guide assembly relative to the welding torch;
• conveying the filler wire from the drive mechanism to the welding tip of the welding torch using a wire guide attached by a second bracket to the drive mechanism and having a distal end located proximal to the welding tip
• adjusting an entry angle formed by an axis of the wire guide relative to a horizontal plane using the arced tube member;
• and
• adjusting the position of the wire guide relative to the welding tip using a first adjustor and a second adjustor attached to the second bracket, the first adjustor and the second adjustor adapted to move the wire guide along axes perpendicular to one another and to a longitudinal axis of the wire guide.

A wire guide apparatus for use with a welding system, the wire guide apparatus comprising:

• drive means for moving weld wire from a weld wire supply to a location proximal to a welding tip of a welding torch, the drive means attached to the welding torch of the welding system by a mounting arm adapted to adjust a position of the drive means in relation to the welding torch;
• guide means for positioning the wire guide relative to the welding tip, the guide means attached to the drive means;
• adjustment means for adjusting the position of the wire guide relative to the welding tip;
• and
• wherein the mounting arm includes a first bracket attached to the welding torch and a tube member attached the drive means, the tube member in sliding engagement with the first bracket to vary the position of the drive means and the wire guide relative to the welding torch, and the tube member arced to change an entry angle formed by an axis of the wire guide relative to a horizontal plane.

A wire guide apparatus for use with a welding system, the wire guide apparatus comprising:

• a drive mechanism attached to a welding torch of the welding system;
• a guide assembly attached to the drive mechanism, the guide assembly comprising:
• a second bracket by which the guide assembly is attached to the drive mechanism;
• a wire guide through which the filler wire is passed, the wire guide having a distal end located proximal to a welding tip of the welding torch;
• and
• a first adjustor and a second adjustor attached to the bracket of the guide assembly to position the wire guide relative to the welding tip, the first adjustor and the second adjustor adapted to move the wire guide along axes perpendicular to one another and to a longitudinal axis of the wire guide;
• and
• a flexible conduit through which the filler wire is passed, the conduit extending from a location near to a filler wire supply to the drive mechanism, and wherein the wire guide apparatus further comprises a pulley assembly having a pulley attached to the drive mechanism by an articulated bracket, the pulley assembly adapted to receive the conduit from any direction and convey the conduit to the drive mechanism along a substantially straight path tangential to the pulley.

In a welding system having a welding torch with a welding tip for welding a workpiece, a method of feeding filler wire comprising steps of:

• drawing the filler wire from a supply using a drive mechanism attached by a mounting arm to the welding torch, and a pulley assembly having a pulley attached to the drive mechanism by an articulated bracket, the pulley assembly adapted to receive a flexible conduit through which the filler wire is passed from any direction and convey the conduit to the drive mechanism along a substantially straight path tangential to the pulley;
• conveying the filler wire from the drive mechanism to the welding tip of the welding torch using a wire guide attached by a bracket to the drive mechanism and having a distal end located proximal to the welding tip;
• and
• adjusting the position of the wire guide relative to the welding tip using
• a first adjustor and a second adjustor attached to the bracket of the guide assembly, the first adjustor and the second adjustor adapted to move the wire guide along axes perpendicular to one another and to a longitudinal axis of the wire guide.