FIELD OF THE INVENTION
The present invention relates to a device for removal of rust from continuously
fed filler wire from spools to produce improved welding. The invention further
relates to a method for removing rust from filler wire to produce improved
quality welds without interruption in the production welds.
BACK GROUND OF THE INVENTION
The heat generated in the combustion process in a boiler appears as furnace
radiation and sensible heat in the products of combustion. Water circulating
through the tubes that forms the furnace wall lining absorbs this heat and in turn
generates steam by the evaporation of the part of the circulating water. The
water walls usually consist of vertical tubes arranged in tangent or approximately
so, connected at top and the bottom to headers. These tubes receive the water
from the boiler drum by means of down comer pipes connected between bottom
of the drum and the lower headers. Both carbon steel and alloy steel tube
materials are used in the manufacturing of water wall panels.
20 Torch Membrane Panel Welding Machine and Panel Processing machines
(PPM) are used for the fabrication of water wall panels. The fabrication process
of water wall panels with these machines uses electrode which is in the form of
drum packs or Spool Coils. Every year, more than 500 tons of filler wire is
procured and being consumed in the production shops in the fabrication of water
wall panels. These filler wires may get rusted due to moisture in the atmosphere,
improper storage in yards and some time due to unused filler metal remaining in
opened condition for long period.

The cost of the drum pack or spool coil is too high for it to be condemned. But
the use of rusted filler wire may cause numerous problems during welding. This
includes the interruption in welding due to the hindrance in the flow of current
caused by the rust. The arc stability will be lost, thus affecting the continuous
deposition of filler wire. The rust in the filler wire may get accumulated in the
liner and wire feeder, thus creating problems in wire feeding. It may also
introduce porosity in the weld metal, thus reducing the quality of the weld. The
amount of rework to be done in the panel will be considerably high when it
comes out of the machine. Thus the cost of rework is increased, thereby
resulting in increased cycle time of panel processing.
This Invention is meant for cleaning the rust from filler wire which is
continuously fed from the spools or drum packs. It is an innovative device for the
removal of rust from both solid and flux cored filler wires to produce improved
quality of welds without interruption in the production welds.
MAO TIANPING (CN202021534) discloses a shell-peeling and rust-removing
device for production of welding wires a shell-peeling and rust-removing wheel
arranged on the upper end surface of the support plate and a soft metal steel
wire brush wherein a coil rod inlet and a coil rod outlet are arranged on two
opposite side walls respectively and the soft metal steel wire brush is arranged
on the outer side wall of the box body and positioned at the end of the coil rod
outlet. By adopting the structure, the shell-peeling and rust-removing device is
simple in overall structure and convenient for operation and implementation.

ZHANG JIANZHONG (CN201632398) discloses a surface wiping device of a flux-
cored wire, which is mainly used for treating the surface of the flux-cored wire
and belongs to the technical field of mechanical equipment. The surface wiping
device of a flux-cored wire is characterized by comprising a support dance
wheels, a housing and a motor wherein the housing is arranged on the support,
both ends of the housing)-are respectively provided with the dance wheels one
of the dance wheels is in transmission connection with the motor below the
support and wiping cloth is arranged in the housing. The surface wiping device of
a flux-cored wire can remove impurities comprising dust, lubricants and the like
on the surface of the wire before oiling to ensure subsequent oiling uniformity,
thereby improving wire feeding performance, moisture prevention and rust
resistance of the wire.
SUMMARY OF THE INVENTION
Accordingly, there is provided a device for removing rust from continuously fed
filler wire used for manufacture of water wall panels using Panel Formation
machines, comprising a polyethylene hose filled with multiple iron balls, a
plurality of hose clips and a first hexagonal nut with first and second integrated
sleeves to provide abrasion action in the hose to remove the rust from the wire,
the iron balls are arrested inside the hose by providing said hose clips at a
primary end for passing the wire and a third sleeve with a second hexagonal nut
at a secondary end for connecting the hose with the wire feeding conduits of
welding torches.

According to the inventive device, the rust cleaning from continuous fed filler
metals from spools or drum packs can be achieved. Further, the interruption
during the welding process is minimized. The removal of rust from both solid and
flux cored filler wires produce improved quality of welds without interruption in
the production welds.
In case of flux cored filler metals, the roundness of the filler wire is not affected
since the device consists of iron balls which do not impart any pressure on the
filler wire.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Figure 1 - shows a rust cleaning device according to the invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
As shown in Figure 1, the rust cleaning device consists of polythene hose (1)
filled with Iron balls (6) and are arrested inside the hose (1) by providing a first
hexagonal nut with an integrated sleeve (3) using a first hose clip (2) at the
primary end, a second hexagonal nut with an external threaded integrated sleeve

(4) and an internal threaded plain sleeve (5) and a second hose clip at the
secondary end of the hose (1) facilitating replacement of the Iron balls. A hole in
the integrated sleeve (3) at the primary end permits the rusted welding wire to
pass through the Iron balls disposed in the hose (1) which cleans the rust in the
wire by rotary friction motion and another hole in the hexagonal threaded
integrated sleeve (4) at the secondary end releases out the cleaned wire to the
wire feeder of the welding machine.

WE CLAIM
A device for removing rust from continuously fed filler wire used for manufacture
of water wall panels using Panel Formation machines, comprising a polyethylene
hose (1) filled with multiple iron balls (6), a plurality of hose clips (2) and a first
hexagonal nut with first and second integrated sleeves (3 and 4) to provide
abrasion action in the hose (1) to remove the rust from the wire, the iron balls
are arrested inside the hose by providing said hose clips (2) at a primary end for
passing the wire ad a third sleeve (5) with a second hexagonal nut at a
secondary end for connecting the hose with the wire feeding conduits of welding
torches.

ABSTRACT

The invention relates to device for removing rust from continuously fed filler wire
used for manufacture of water wall panels using Panel Formation machines,
comprising a polyethylene hose (1) filled with multiple iron balls (6), a plurality
of hose clips (2) and a first hexagonal nut with first and second integrated
sleeves (3 and 4) to provide abrasion action in the hose (1) to remove the rust
from the wire, the iron balls are arrested inside the hose by providing said hose
clips (2) at a primary end for passing the wire ad a third sleeve (5) with a second
hexagonal nut at a secondary end for connecting the hose with the wire feeding
conduits of welding torches.