Dual drive wire feeding wheel

The dual drive wire feeding wheel is the core component of the welding wire feeding system, which adopts a four-wheel dual drive symmetrical clamping structure (two sets of active wheels+two sets of wire pressing wheels to clamp the welding wire). The welding wire is smoothly conveyed through dual power sources or synchronous transmission mechanisms. Compared with the single drive wire feeding wheel, its core advantages are good wire feeding accuracy, strong clamping force, and wide adaptability. It is widely used in automated welding scenarios such as gas shielded welding (CO ₂/MIG/MAG) and argon arc welding. The following is a detailed characteristic analysis:

Core Structure and Materials

1. Structural design

Dual drive core architecture: The mainstream design is a four-wheel dual drive bracket, with two sets of wire feeding wheels symmetrically distributed vertically. Equipped with dual adjustment handles to independently control the spacing between wheel sets, it can be finely adapted to the clamping requirements of different diameter welding wires, avoiding the slip problem that is prone to occur in single drive structures.

Wheel specifications: The standard wheel diameter is Ø 40mm, and double groove design is commonly used (some models support 3 grooves). The groove type is subdivided according to the welding wire material - V-shaped groove is suitable for hard welding wires such as carbon steel and stainless steel (with a tension angle of about 40 ° and a wire feeding force 10% -30% higher than flat wheels), U-shaped groove is suitable for easily deformable materials such as aluminum wire and flux cored welding wire, and trapezoidal groove balances stability and versatility, resulting in better wire feeding effect.

Auxiliary structure: The bracket is mostly made of aluminum alloy material, balancing lightweight and rigidity; The pressure arm adopts a dual arm forward push release structure, which facilitates the loading and unloading of welding wire. Combined with the straightening mechanism, it can reduce the bending of welding wire and avoid the risk of wire blockage.

2. Material selection

Wheel body body: Made of high hardness bearing steel (GCr15) or alloy steel, with a hardness of 58-63HRC after quenching heat treatment. It has outstanding strength in terms of wear resistance and fatigue resistance (based on actual reports), and can withstand the friction force of welding wire transport for a long time.

Special model: For high-frequency welding or high hardness welding wire scenarios, hard alloy coated wheel surfaces can be optionally selected to further extend the service life.

Transmission components: The motor often uses a combination of delicate DC flat motors and alloy steel gear reducers. Some models are equipped with the invented word-of-mouth worm gear motor, which has suitable response speed and excellent braking performance, and is suitable for high-frequency inverter welding machines and high-speed welding needs.

Key performance parameters

Suitable welding wire range: The mainstream specifications cover welding wires with diameters ranging from 0.4-1.6mm. Common sub models include 0.4/0.6mm (wire to wire one-to-one), 0.8/1.0mm, 1.0/1.2mm, 1.2/1.6mm, compatible with solid core welding wire, flux cored welding wire, stainless steel wire, aluminum wire, silver copper alloy welding wire and other materials.

Wire feeding speed: The conventional adjustment range is 1.5-30m/min, and some excellent models can reach up to 30m/min faster (such as NB-630HK pro). The low-speed stability is excellent, and even wire feeding can be achieved at a lower speed of 45mm/min. It is suitable for thin plate fine welding and thick plate effect welding scenarios.

Drive capability: Output speed 0-250r/min, motor power can be selected from 50W, 110W and other specifications. The wire feeding thrust is large, which can effectively overcome the resistance caused by the bending of the wire feeding hose and reduce the problem of poor wire output.

Functional scalability: Some supporting wire feeders support three modes of wire feeding: early wire feeding, synchronous wire feeding, and long-term wire feeding. The wire feeding time and retraction time can be finely adjusted (0.01-99.9 seconds), and also have functions such as jog wire feeding, retraction, and wire breakage protection, with strong operational flexibility.

Core strengths

Strong wire feeding stability: The dual drive symmetrical clamping design ensures even force distribution on the welding wire, avoiding wire feeding shaking and deviation caused by the "single point force" of the single drive structure. Combined with detailed groove and straightening mechanisms, it can significantly reduce welding spatter, porosity, lack of fusion and other defects, resulting in a high success rate of arc ignition.

Widely applicable scenarios: compatible with various welding modes such as CO ₂/MIG/MAG, argon arc welding, etc., suitable for welding machines and robot welding systems of specifications such as 350A and 500A. It can meet the requirements of fine welding of thin plates (such as plates below 0.8mm) and thick plate effect welding (such as structural parts above 20mm).

Excellent practicality and maintainability: The high hardness material and optimized structural design extend the service life, and some models have a warranty period of up to six months; Easy maintenance, cables with clear wire number markings, no need to focus on electrical knowledge to quickly replace parts.

Convenience of operation: The dual adjustable handle can adjust the clamping pressure at a suitable speed and adapt to different materials of welding wire; Some models support welding/stop welding switching function, which allows adjusting the length of the welding wire without turning off the power of the welding machine, avoiding frequent power on/off and affecting the service life of the equipment.