Field of the invention

The present invention belongs to the field of welding, more precisely to the field of auxiliary devices for improving the welding process. The invention relates to a device for storing and automatic dispensing of welding materials, especially filler materials such as welding wire to users based on work orders. In addition, the invention also relates to a method of dispensing materials for welding.

Background of the invention and the technical problem

Welding is a fabrication process that joins materials, usually metals, by causing fusion, which includes melting of a base metal. In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint, which is usually stronger than the base material. Filler metals are alloys or unalloyed metals which, when heated, liquefy and melt. Standard filler metals include tin, lead, silver, lead-free, cadmium-free, copper, aluminium, nickel, and jeweller’s gold. Filler metals are found in solid form, such as rings and wire, slugs, washers, powder, as well as paste.

The welding process requires a lot of control in order to achieve high quality. This has been regulated by several standards such as ISO 9001 , EN 1090 and in particular ISO 3834, which provides criteria to be taken into account for the selection of the appropriate level of quality requirements for fusion welding of metallic materials. A need for a quality management system has been expressed on multiple occasions, especially in larger companies in which control and use of filler material is impaired. More importantly, some filler materials may not be mixed with each other; therefore it would be beneficial if the use of filler materials was controlled. In order to provide surveillance and improve quality of the welding process some companies employ welding supervisors. However, it is a difficult task to efficiently keep track of filler material consumption as welding processes are constantly in progress, often at multiple locations of manufacturing halls or building sites. Therefore, the technical problem solved by the present invention is to provide and design an automatic device for storing, controlling access and dispensing filler materials before the start of welding, so that the process is performed with a correct filler material or combination thereof. In this way quality, efficiency and economy of welding could be improved.

State of the art

The above described technical problem has not been addressed so far. There are several solutions addressing storage and supply of filler materials such as welding wire, but they are for use at the place of welding during the process itself. One such solution is described in patent EP0313232, which relates to a filler wire feed controller for a welding system. The wire is supplied to a weld pool at a rate at which it is consumed and deposited on a workpiece.

Document CN107520520 discloses a material shortage monitoring device of an automatic wire guide machine based. The monitoring device comprises a sensor for detecting whether a metal wire exists or not, so that the automatic wire guide machine for electric welding can be interrupted during material shortage to feed wires to the welding position continuously.

Utility model CN206634853 discloses an automatic collecting device of welding wire with an on-line screen storage device. Another utility model CN202278286 describes a welding wire storage device which is used so that an adjusting nut is twisted to retract a telescopic bracket, a fastening bolt is then released, a pressure rod is rotated, and a welding wire disc is mounted; and then the fastening bolt is screwed, the adjusting nut is rotated to tension the welding wire disc. This solution realizes stable delivery of welding wire at the welding line.

Although all described solutions aim to improve welding quality and efficiency, the welders still have to obtain the appropriate, i.e. required, filler material independently of these devices. Thus, the problem of controlled access to filler materials and their dispensing remains unsolved.

Description of the solution of the technical problem

The essence of the present invention is that the device for storing and dispensing materials for welding, preferably filler materials, is designed as a vending machine, which dispenses the appropriate welding material based on work orders. These are stored on magnetic keys, cards or similar suitable media, which can interact with a user interface of the device. The device comprises a frame, which has a carrier part on which rotation means, a motor and welding material dispensing means are mounted . A head with at least one storage element for housing filler materials and a base is positioned on rotation means, so that the head can be rotated upon activation of the motor. When the head reaches the required position, the suitable welding material is dispensed with dispensing means and the user can take it from the device. The head may be removable and replaceable. All elements of the device are housed within a housing, which protects the materials and prevents access without authorization. The device activates dispensing of filler materials only if the user’s magnetic key, card or suitable medium contains a work order for this material. In this way, the device controls access to filler materials and contributes to proper use.

Operation of the device according to the invention is supported by a computer and computer program, which executes at least the following activities:

- storing and processing information regarding position of each welding material type,

- reading and processing work orders, - initiating delivery of filler materials based on work order by recognizing where the required material is stored, by activating the motor to rotate the head so that the required material reaches dispensing means and by activating an actuator of the dispensing means,

- obtaining, forwarding and storing information about dispensed filler materials in order to track stock and control welding activity.

The process of dispensing filler materials with the said device comprises the following steps:

- reading a work order from the magnetic key, card or any another suitable storage medium placed on, in or near the user interface 1 1 a on the housing 1 1 ,

- recognizing which material(s) is(are) required,

- retrieving information about the position of required material,

- initiating motor and rotation of the head to achieve the correct position,

- when the suitable filler material is located above dispensing means, rotation is terminated and filler material is dispensed with dispensing means and the user can take it through the dispensing part of the housing.

In case several materials are needed according to the work order, the motor and rotation are initiated again for dispensing the next material, but only when the previous material has been taken out from the device.

The invention will be further described based on preferred embodiments and figures, which show:

Figure 1 The device according to the invention

Figure 2 Side view of the device interior without the head with storage elements Figure 3 Side view of the device interior with the head with storage elements Figure 4 Front view of the device interior with the head with storage elements Figure 5a Back side view of the device interior with the head with storage elements

Figure 5b Detail A

Figure 6a The head with storage elements Figure 6b Base of the head

Figure 6c Cross section of the head

Figure 7 A possible embodiment of the clamps of the base

Figure 8 Closings and links of the storage elements

Figure 9 A possible embodiment of the tube for the head with storage elements Figure 10a A possible embodiment of the rotation drive

Figure 10b A possible embodiment of rotation means

Figure 10c The shaft and the flange of rotation means

Figure 10d The tube for the shaft

Figure 1 1 A possible embodiment of an actuator of the dispensing means

Figure 12a Front-side view of the drawer of the dispensing means

Figure 12b Back-side view of the drawer of the dispensing means

Figure 13 Apertures in the base of the head for sensing the head position

The device 1 for storing and dispensing materials for welding, which are preferably filler materials, comprises:

- the interior of the device comprising:

o a frame 2,

o the frame 2 having a carrier part 21 in the lower half of the frame, on which rotation means 3, motor 4 and means for dispensing 5 filler material are mounted,

o a removable and replaceable head 6 with a base 63 and at least one storage element 62 arranged to hold filler materials, the head being placed on rotation means 3 so that can be rotated upon activation of the motor 4,

- a housing 1 1 for enclosing the interior of the device 1 , which comprises:

o a user interface 1 1 a for interaction with user’s magnetic key, card or any other suitable media tor carrying work orders, and

o a dispensing part 1 1 b, through which the filler material can be obtained.

The frame 2 is preferably shaped as a cuboid with defined four sides and is preferably made of iron, steel, aluminium or any combination of these materials or sheet material. The carrier part 21 is located in the lower part of the frame 2 and is provided by at least one, preferably two or more parallel bars in the centre of the carrier part 21 as shown in Figure 2. These bars are made of the same material as the frame 2. The carrier part

21 is preferably at 15 to 45 % of the height of the frame 2, more preferably at 20 to 25% of the frame height, so that the head height can be optimized with respect to the type of materials to be stored. The carrier part 21 may have further support elements

22 as shown in Figures 3 and 5. These support elements provide better support for the head as well as the whole construction. The carrier part 21 of the frame 2 may also be reinforced with vertical profiles in order to further improve stability of the device. The frame 2 may also have guides for a fork lift, so that the device may be moved between several locations. For improving device manipulation the bottom part of the housing 1 1 may have additional reinforcements. The frame may also have secondary guides for a fork lift below the head, so it can be easily lifted and replaced by a new head.

The housing 1 1 , which surrounds the whole structure, is adapted to the shape of the frame 2 and is preferably made of sheet metal (tin) or any other suitable material including plastic material. Because the device may also be placed outside, the housing may have an additional water-impermeable layer in order to prevent water from entering the interior of the device. The housing 1 1 is made from several parts. The front part of the housing 1 1 may have a door 12, which is designed as a one-winged or two-winged door, through which the device 1 can be serviced. It is also possible to lift and remove the housing 1 1 for easier access during service and repair. As shown in Figure 1 the dispensing part 1 1 b is located below the door 12, while the user interface 1 1 a is usually located on the left or right side of the door 12. The door 1 2 may have window panels 12a, so that the interior is visible from the outside. Flowever, this embodiment is less preferred in order to prevent interference with sensors inside the device 1 . The backside of the housing 1 1 may be made from one, two or more sheets, however individual sheets are preferably screwed together so that opening of the device 1 from the back is prevented.

The motor 4 may be an electromotor and can be powered in any suitable way, for example by a battery, solar power or by electricity. Ensuring that the motor 4 is powered is done in known ways. The preferred embodiment includes battery or solar power, as such device does not need to be plugged into an electric plug. Consequently, the device 1 according to this embodiment can be placed anywhere where it is needed regardless of power supply. The motor 4 is connected to the frame 2, below the rotation means 3 in the carrier part 21 , however the connection of the motor 4 to the frame 2 is preferably not direct but via a connecting part, so that the motor can be easily removed and replaced. The motor 4 has a brake 41 , which is controlled by the computer program. An emergency button is preferably provided on the housing 1 1 of the device 1 to stop the operation of the motor 4. The motor 4 and rotation means 3 are connected (Figure 10a), so that the motor 4 can rotate the rotation means 3 and consequently the head 6. The speed of rotation may be regulated by the computer program, so that rotation of the head 6 is not abruptly terminated upon reaching the required position. When the doors 12 of the housing 1 1 are open, the motor 4 cannot be started and rotation of the head 6 is consequently disabled. In this case, it is possible that the head is not in the correct position (for example when refilling the device), therefore the device 1 also has means for manual rotation. At least one button is provided in order to turn the head for one or more positions. Manual rotation is also useful for events when the motor cannot be started due to a failure or lack of power.

As shown in Figure 10b rotation means 3 comprise a carrier plate 31 , which has a cone-like element 32 in the middle. Below the plate 31 is a housing 33a housing a hollow part 33 of the rotation means 3 shown in Figure 10a. The rotation means 3 further comprise a shaft 34, a flange 34a, a tube 35 for the shaft and the housing 33a. Figure 10c shows an embodiment of a shaft 34 having a flange 34a, the diameter of the shaft 34 slightly decreasing towards the opposite part of the flange, which is to be inserted in the rotation drive connected to the motor 4, which are shown in figure 10a. The shaft has several parts having different diameters, preferably at least two - wider part 34b and narrower part 34c. The shaft is arranged in a shaft tube 35 shown in figure 10d, wherein the most of the tube is placed in the housing 33a. The shaft tube 35 may have a cross-section as shown in Figure 10d, wherein it is shown that the shaft tube 35 is made of several tubes (35a and 35b) interconnected with each other by linking elements (35c), which are preferably welded to the tubes. In addition, the tube 35 may have additional shaft stabilizations 35d for stabilizing the head 6, especially during rotation. Preferably, rotation means 3 are also equipped with an element for protection from dust. The shaft is preferably made of iron, steel, more preferably reinforced steel, and is inserted into the rotation drive. The shaft is fixed by the shaft key, which ensures connection with the motor 4 so that upon activation of the motor 4 the rotation means 3 rotate. The central axis of the rotation means 3 is coaxial with the head 6, which is placed on the rotation means 3. The head 6 has to be placed correctly on the rotation means 3 so that the position of the storage elements 62 overlies the dispensing means

5, through which the welding materials are made available for dispensing. This is enabled with a system of openings and sensors, preferably 3 sensors are used so that one is below the openings as shown in figure 13. There are three slots for each storage element, based on which the sensors can determine whether it is in the correct position. Thus, if a signal between the sensors is interrupted, the position is not correct. Recognition of positions is linked to the computer, which also controls rotation so that based on sensors the program regulates whether the rotation has to be terminated or not.

The head 6 is shaped as an approximate cylinder and has a central tube 61 connected with the rotation means 3, so that rotation in both directions (clock-wise and counter clock-wise) is enabled. The tube 61 shown in figure 9, which is the central axis of the head 6, is made with two star-shaped elements (61 a and b), one on the lower part and one on the upper part. The upper part of the tube 61 is equipped with a hook 61 1 in the centre to enable lifting with a suitable machine. The head 6 has at least one storage element 62 or up to 12 storage elements 62, depending on the number of different filler materials that have to be dispensed. Storage elements 62 may preferably be 2, 3, 4,

6, 8, 10 or 12, most preferably 6 as shown in figures 3 to 6. They can be filled with one type of welding material or with several different types, for example six different types in 6 storage elements. It is important to keep track of the location of each welding material, so that correct materials are dispensed. Storage elements 62 are shaped depending on their number, for example in case of two storage elements they have a semi-circular cross shape, while in case of 4 or more they are shaped as cylinders or hexagonal prisms. The shape of storage elements also depends on the material stored in them. The preferred embodiment of storage elements 62 is shaped as a hollow hexagonal prism, having a height which allows storage of up to 12 discs with welding wire. It can be made from two symmetrical parts, which are held together with a special hinge 62b shown in Figure 8. The storage elements may be linked together with links 62a as shown in Figure 8 for improved stability. The storage element may have holes 621 in order to reduce their weight. The preferred embodiment of the head 6 has six storage elements as shown in figures 3 to 6 and 8, each storing up to 12 discs of welding wires.

Storage elements 62 are mounted on a central part of the head 6, as well as on the circular base 63, i.e. carrier of the head. When placed on the base 63 the storage elements 62 may be connected to each other for improved stability as shown in figure 8. As the head 6 is heavy, leaning to left or right side is prevented by providing special ball elements below the base 63, so that the base 63 can rotate and slide on these ball elements. The exact shape of the base 63 depends on the number of storage elements 62 and corresponds also to their shape. An embodiment of the base 63 is shown in Figure 6b. The tube 61 is received by the circular middle part of the base 63, while each storage element 62 is received by its carrier. The base 63 comprises a clamp 631 for each of the storage elements 62, wherein the clamp 631 is situated below the storage element 62, so that all materials in the element 62, except the first one, are above the clamp 631 . The first one is located in the clamp 631 , preferably holding the whole circumference of a disc with welding wire. A possible embodiment of the clamp 631 is shown in Figure 7. It has an opening 631 a for receiving an actuator 51 of the dispensing means 5, a spring 631 b placed in the opening 631 a and distancing elements 631 c. The clamp is made from iron and the spring has a preferred strength of 2 kg Nm. A possible actuator 51 is shown in figure 1 1 . It has a projecting part 51 a that can extend and thereby interfere with the clamp 631 to release it. The actuator 51 is controlled by the computer program.

When one unit of the filler material has to be dispensed, the said clamp 631 is temporarily released by an actuator 51 shown in figure 5b and 1 1 . This is controlled by the computer program. The actuator 51 is a part of the dispensing means 5, which also includes a movable element 52 (Figure 12), such as a tray or a drawer that can be moved towards the exterior of the device. The device 1 could be without the movable element, but the movable element increases safety of users. The actuator 51 lifts the whole storage element 62 and hits the opening of the clamp 631 so that the spring is pulled apart. Thereby the clamp 631 is released, so that one unit of filler material, for example one disc of welding wire, drops into the movable element. Thereby a lock of the movable element is released, so that the dispensing part 1 1 b of the housing 1 1 connected to the movable element can be pulled out and the dispensed welding material can be taken from the movable element. Sensing of dispensed material in the dispensing means is usually done with sensors, but it can be done in any suitable way. When the material is taken out, the movable element can be returned to its starting position and is locked. Return (closure) of the movable element may be automatic provided that the materials have been taken out. The lock may be any suitable locking mechanism, preferably based on sensors. Dispensing means 5 may also be supported with a computer program; however, this is not essential.

The preferred embodiment of the movable element is a drawer, which is shown in Figures 12a and 12b. The drawer 52 has a front surface 52a preferably provided with a pulling element 52a’ to allow easy (effortless) pulling the drawer from the interior of the device. Further, the drawer is equipped with a base 52b, preferably with an opening to reduce weight, and two sides 52c which are provided with suitable rails that allow pulling the drawer out and back. Preferably, the drawer is locked with mechanical means, such as a spring and a lock, so that the weight of the welding materials presses on the mechanic means and it releases the spring which releases the lock and the drawer can be pulled out. Alternatively, this could be sensed with a suitable sensor 52d, which is shown in Figure 12a. The drawer cannot be put back into its original position without taking the materials, as the spring will not allow locking. The drawer can be additionally protected with sensors. This solution ensures that no one will be able to leave the material in the device, which further prevents trouble with device operation. It is also possible to implement snail like rotation of materials in individual storage elements, however this solution is more complicated.

The head 6 and/or storage elements 62 can be refilled directly in the device or by replacing it with a new, full head 6. The storage elements 62 are equipped with the hinge 62b, which has to be released so that the storage element 62 is opened in order to add new discs with welding wire. Storage elements 62 of the head 6 are filled with welding materials and the location of each material has to be entered into the computer program. The material can be scanned by the product code and then placed in the storage element 62 so that tracking is improved. In case the position of materials changes, this has to be entered into the computer program.

When a storage element 62 is empty, this is sensed by the sensor assembly, where one sensor is located above the storage element 62 and one sensor is located below the storage element, for example in the dispensing part 5 of the device 1 . When the sensors cannot communicate (for example a signal from one sensor cannot reach the other sensor), the storage element 62 still contains welding materials. However, as soon as the storage element is empty, the signal will be able to reach the other sensor and thus the computer program will receive information that the storage element 62 at a certain position is empty. Based on data in the computer program, the material management will be able to track material consumption and order to materials or re filling of the head 6 and/or storage element 62.

When filling or re-filling the storage elements, the first unit of welding materials (for example one disc of welding wire) has to be placed in the clamp 631 and it is important to ensure that this unit does not block the actuator of the 51 of the dispensing means 5. The dispensing means 5 preferably comprise an additional blockage to ensure that the disc is placed appropriately. Other units of welding materials are placed on top of the first, wherein the second and all following units are located above the clamp 631 . Each part of the device, for example the movable element, storage element, actuator, etc. is a separate element, which can be assembled outside the device and can be easily exchanged with the old one, in case the old one has been damaged.

The device 1 operates in such a way that a user puts the magnetic key, card or any other suitable medium on, in or near the user interface 1 1 a and thus triggers reading of work order(s) stored on the medium. A preferred embodiment also includes a confirmation of the information stored on the read medium, in a form of typing the work order number or providing a case or person sensitive code. Such confirmation ensures that the correct person has initiated the process. If there is no work order, the device will not issue any filler material. If the work order comprises specific filler material or combination of filler materials, the device recognizes where these materials are stored based on the data stored in the device’s computer program. The head 6 is rotated due to activation of the motor 4 and rotation of rotating means 3. When the head 6 reaches the required position, so that the suitable filler material is located above dispensing means 5, rotation is terminated and filler material is dispensed with dispensing means 5 and the user can take it through the dispensing part 1 1 b of the housing 1 1 . Preferably, after rotation is termination the actuator 51 is activated in order to raise the storing element 62 so that its clamp 631 releases one unit of filler materials into the dispensing means, preferably the drawer. After that, the movable element of the dispensing means is unlocked, so that dispensed filler material can be taken. Preferably, the drawer is locked with mechanical means, such as a spring and a lock, so that the weight of the welding materials presses on the mechanic means and it releases the spring which releases the lock and the drawer can be pulled out. The drawer cannot be put back into its original position without taking the materials, as the spring will not allow locking. The drawer can be additionally protected with sensors. This solution ensures that no one will be able to leave the material in the device, which further prevents trouble with device operation.

Because the filler material is only issued if the work order contains it, it is ensured that the welder obtains the proper material. In this way increased quality of welding is achieved, as the correct materials are used and no unallowable combinations can be made. In case the work order comprises more filler materials, the process for delivering second material is initiated from the step of motor activation after the dispensing part is closed.

Filler materials stored in the device are preferably welding wires but can also be any other materials such as electrodes, rings, slugs, washers, powder, as well as paste.

The device for storing and dispensing filler materials for welding eliminates the need for welding supervisors or at least reduces their workload, ensures that the appropriate materials are used so that combination of non-compatible filler materials is prevented and further allows monitoring of consumption and activity of welders. Thus, quality, efficiency and economy of the welding process are improved. Further, the device also enables safe storage of filler materials and tracking their quantity, thus providing direct information for the purchasing department when and how much of filler material has to be ordered.

The device for storing and dispensing filler materials for welding according to the invention can be placed in manufacturing halls, in storage halls, construction sites or anywhere else where it is needed. Its design allows movement and transport, so that it can be moved between several locations at one construction site or between several construction sites and production halls. The preferred dimensions of the device are 1 .5 m (length), 1 .5 m (width) and 2 m (height).

During design of the device it has been established that it is suitable to store and dispense also other materials connected with welding as well as general construction, such as wires (not for welding), cables, rubber tubes (for insulation), aluminium and similar. Thus, the invention is not limited only to the device for storing and dispensing welding materials, but also to the device for storing and dispensing other constructi on materials, so that the overall construction process can be improved by ensuring correct use of materials and enhanced tracking of stocks. The invention as herein described and defined in the appended claims allows designing different embodiments of the device for storing and dispensing welding materials, which are clear to a skilled person. The described embodiments do not limit the essence of the invention as defined in the claims.