Smart Drive Roll Assembly

Abstract

Systems and methods are provided for manually setting up a wire drive assembly of a welding power supply and automatically setting up welding power supply parameters. A drive roll is configured with multiple grooves for receiving multiple wires of different types and/or different diameters. A sensor can detect the configuration of the drive roll such as, for example, being configured to receive a particular wire type with a particular diameter in a particular groove, by detect a distance to the drive roll. The welding power supply can use this information to automatically set the wire speed.

1 . A wire drive assembly, comprising:
 a drive roll having a plurality of configurations; and   a sensor configured to detect which of the configurations has been set based on a distance to the drive roll.   
     
     
         2 . The wire drive assembly according to  claim 1 , wherein the drive roll is configured to receive a wire having at least one of a wire diameter or a wire type, wherein the sensor is configured to detect at least one of the wire diameter or the wire type based on the distance to the drive roll. 
     
     
         3 . The wire drive assembly according to  claim 1 , wherein the drive roll is configured with a first groove and a second groove, wherein the first groove is configured to receive a first wire having a first diameter, and wherein the second groove is configured to receive a second wire having a second diameter. 
     
     
         4 . The wire drive assembly according to  claim 4 , wherein the sensor is configured to determine whether the drive roll has been set to receive the first wire having the first diameter or the second wire having the second diameter based on the distance to the drive roll. 
     
     
         5 . The wire drive assembly according to  claim 1 , wherein the drive roll is configured with a first groove and a second groove, wherein the first groove is configured to receive a first type of wire, and wherein the second groove is configured to receive a second type of wire. 
     
     
         6 . The wire drive assembly according to  claim 6 , wherein the sensor is configured to detect whether the drive roll has been set to receive the first type of wire or the second type of wire based on the distance to the drive roll. 
     
     
         7 . The wire drive assembly according to  claim 7 , wherein the first type of wire is a solid wire, and wherein the second type of wire is a flux-cored wire. 
     
     
         8 . The wire drive assembly according to  claim 1 , wherein the drive roll has a plurality of slots, and wherein each of the plurality of slots corresponds to one of the plurality of configurations. 
     
     
         9 . The wire drive assembly according to  claim 9 , wherein the drive roll is installed on a drive shaft with a pin, and wherein the pin engages with one of the plurality of slots to set one of the plurality of configurations. 
     
     
         10 . The wire drive assembly according to  claim 10 , wherein the drive roll is set at a particular location on the drive shaft when the pin engages with one of the plurality of slots. 
     
     
         11 . A wire drive assembly, comprising:
 a drive roll having a plurality of configurations relating to receiving different types of wire on different grooves; and   a sensor configured to detect which of the configurations has been set based on an angle through which the drive roll is rotated in setting one of the plurality of configurations.   
     
     
         12 . A welding power supply, comprising:
 a wire drive assembly including
 a drive roll having a plurality of configurations, and 
 a sensor configured to detect which of the configurations has been set based on a distance to the drive roll; and 
   one or more processors operatively coupled to the sensor.   
     
     
         13 . The welding power supply according to  claim 13 , wherein the one or more processors are configured to automatically determine which of the configurations has been set based on a signal received from the sensor. 
     
     
         14 . The welding power supply according to  claim 14 , wherein the drive roll is configured to receive different wires with different diameters, and wherein the sensor is configured to detect the diameter of the wire based on a distance to the drive roll. 
     
     
         15 . The welding power supply according to  claim 15 , wherein the one or more processors are configured to determine the diameter of the wire based on the signal received from the sensor, and wherein the one or more processors are configured to automatically set a wire speed based on the diameter of the wire. 
     
     
         16 . The welding power supply according to  claim 13 , wherein the drive roll is configured to received different types of wire, and wherein the sensor is configured to sense a type of wire based on a distance to the drive roll. 
     
     
         17 . The welding power supply according to  claim 13 , wherein the drive roll is configured with a first groove and a second groove, wherein the first groove is configured to receive a first wire having a first diameter, and wherein the second groove is configured to receive a second wire having a second diameter. 
     
     
         18 . The welding power supply according to  claim 18 , wherein the sensor is configured to determine whether the drive roll has been set to receive the first wire having the first diameter or the second wire having the second diameter based on the distance to the drive roll. 
     
     
         19 . The welding power supply according to  claim 13 , wherein the drive roll is configured with a first groove and a second groove, wherein the first groove is configured to receive a first type of wire, and wherein the second groove is configured to receive a second type of wire. 
     
     
         20 . The welding power supply according to  claim 13 , wherein the drive roll has a plurality of slots, and wherein one of the plurality of slots corresponds to one of the plurality of configurations.