Abstract: A welding end assembly for welding system utilizing a consumable wire electrode. The wire electrode has a non-round cross-sectional shape. The end assembly features a tip having internal bore closely conforming to the cross-sectional shape of the electrode wire. An interaction is provided between an external surface of the tip and an internal surface of the diffuser which establishes a desired indexed orientation of the electrode wire cross-section relative to the end assembly.

Abstract: A gas metal arc welding system for a robotic arm includes a j-arm, a power block, and a bolt. The j-arm has a first end and a second end each having a through hole. The power block has a first opening defining a first passageway along a longitudinal axis and a second opening defining a second passageway substantially along an axis perpendicular to the longitudinal axis. The bolt has a threaded portion configured to extend through the first opening of the j-arm and into the second passageway of the power block, wherein the bolt retains the j-arm to the power block. The threaded portion of the bolt comprises an internal passageway that extends through a longitudinal axis of the bolt, wherein the internal passageway of the bolt and the first and second passageways of the power block are in fluid communication with each other.

Abstract: An end assembly for use with a welding device having a chamber between the diffuser sleeve and the insert which allows for cooling the insert and for controlling the flow of gas through the end assembly. Some of the components of the end assembly such as the contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by a diffuser sleeve constructed of a dissimilar material. The end assembly provides better conductivity of the current through the end assembly for use of less energy during welding.

Abstract: A welding plier includes a first handle and a second handle joined at a pivot point. A spring is disposed between the first and the second handle and biases the first handle away from the second handle. The welding plier also includes a first jaw that extends from the first handle and a second jaw that extends from the second handle. Interior surfaces of the first and second jaws are configured to come into contact with one another when a force is applied to the first handle and/or the second handle so as to overcome the biasing force provided by the spring. The exterior surface of the first jaw and the second jaw each form a step between eight terminal tip portion and a proximal portion.

Abstract: An end assembly for use with a welding device having a contact tip, a diffusor body, and a gooseneck. The contact tip has a convex end surface that contacts and mates with a concave end of the diffuser body. The diffuser body forms a blind bore forming central web and a series of passageways. A longitudinal passageway segment is formed in the contact tip parallel with the central longitudinal electrode bore of the contact tip. A second passageway segment joins the first longitudinal passageway segment. When the contact tip is affixed to the diffuser body, a chamber is formed at the base of the contact tip communicating with the diffuser body passageways. Shielding gas that flows into the diffuser body passes through the web passageways into the chamber and through the first and second passageways of the contact tip to provide shielding gas to the weld site and cool the contact tip during welding operations.

Abstract: A system for transmitting power and current includes a power cable having stranded wires and an exposed end. The stranded wires are ultrasonically welded together. Ultrasonically welding the wires creates a bundle of wires at the exposed end that may be free from air pockets, reducing oxidation and improving the current path through the cable.

Abstract: An end assembly for use with a welding device having a chamber between the diffuser sleeve and the insert which allows for cooling the insert and for controlling the flow of gas through the end assembly. Some of the components of the end assembly such as the contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by a diffuser sleeve constructed of a dissimilar material. The end assembly provides better conductivity of the current through the end assembly for use of less energy during welding.

Abstract: An end assembly for use with a welding device having a contact tip, a diffusor body, and a gooseneck. The contact tip has a convex end surface that contacts and mates with a concave end of the diffuser body. The diffuser body forms a blind bore forming central web and a series of passageways. A longitudinal passageway segment is formed in the contact tip parallel with the central longitudinal electrode bore of the contact tip. A second passageway segment joins the first longitudinal passageway segment. When the contact tip is affixed to the diffuser body, a chamber is formed at the base of the contact tip communicating with the diffuser body passageways. Shielding gas that flows into the diffuser body passes through the web passageways into the chamber and through the first and second passageways of the contact tip to provide shielding gas to the weld site and cool the contact tip during welding operations.

Abstract: A system for transmitting power and current includes a power cable having stranded wires and an exposed end. The stranded wires are ultrasonically welded together. Ultrasonically welding the wires creates a bundle of wires at the exposed end that may be free from air pockets, reducing oxidation and improving the current path through the cable.

Abstract: A flexible wire guide conduit includes a plurality of modules that can be chained together and can pivot and rotate relative to each other. Each module is formed of two halves that are generally mirrors of each other across a mating plane between the halves. Each module includes an upper flange and a lower flange defining a receiving cavity. Each module includes a tongue member sized to correspond to the cavity that is received in the receiving cavity. The flanges include protrusions extending into the cavity to define a pivotable axis. The tongue includes a bore that receives the protrusions of the adjacent module in the chain. The flanges each include a peg extending into the cavity. The pegs are received in slots formed in the tongue and will slide within the slots during pivoting. The pegs and slots define the degree of pivoting permitted between adjacent modules.

Abstract: An end assembly for use with a welding device having a contact tip, a diffusor, an insert, and an gooseneck, and the contact tip has a convex end that contacts a concave end of the insert, and the insert has an opposite end in contact with the gooseneck. The contact tip is threaded into the diffusor at one end of the diffusor, and the gooseneck is threaded into the diffusor at the opposite end of the diffusor, and the insert is disposed within the diffusor and between the contact tip and the gooseneck, such that a conductive path exists between the gooseneck, the insert, and the contact tip. The contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by the diffuser constructed of a dissimilar material.

Abstract: A system for cleaning a weld gun nozzle includes a guide module and a reaming module. The guide module includes a holder assembly that includes a plurality of elongate skid bars. The reaming module includes a rotatable reamer. The skid bars are generally non-rotatable and define an opening into which the weld gun nozzle can be inserted to align the nozzle with the rotatable reamer. The nozzle is guided by the skid bars and inserted over the reamer, which rotates within the nozzle to clean debris from the nozzle. The skid bars are non-rotatable, and can be installed within the holder assembly to be resiliently move radially inward and outward to accommodate the nozzle during insertion.

Abstract: An end assembly for use with a welding device having a chamber between the diffuser sleeve and the insert which allows for cooling the insert and for controlling the flow of gas through the end assembly. Some of the components of the end assembly such as the contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by a diffuser sleeve constructed of a non-conductive material. The end assembly provides better conductivity of the current through the end assembly for use of less energy during welding.

Abstract: A wire guide module for guiding and changing the direction of wire in a wire dispensing system. The wire guide module having an inner passageway with rollers. The rollers adjacent the inner passageway assist the wire in moving smoothly through the wire guide module as the shape of the inner passageway changing the direction of movement of the wire. A wire dispensing system having wire guide modules with rollers which change the direction of the wire while reducing damage to the wire.

Abstract: A conduit constructed from a coiled wire having an oval or elliptical cross-sectional shape.

Abstract: An end assembly for use with a welding device having a chamber between the diffuser sleeve and the insert which allows for cooling the insert and for controlling the flow of gas through the end assembly. Some of the components of the end assembly such as the contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by a diffuser sleeve constructed of a dissimilar material. The end assembly provides better conductivity of the current through the end assembly for use of less energy during welding.

Abstract: An end assembly for use with a welding device having a chamber between the diffuser sleeve and the insert which allows for cooling the insert and for controlling the flow of gas through the end assembly. Some of the components of the end assembly such as the contact tip, insert and gooseneck are constructed of a conductive material which are securely held together in contact by a diffuser sleeve constructed of a non-conductive material. The end assembly provides better conductivity of the current through the end assembly for use of less energy during welding.

Abstract: A conduit constructed from a coiled wire having an oval or elliptical cross-sectional shape.

Abstract: A wire guide module for guiding and changing the direction of wire in a wire dispensing system. The wire guide module having an inner passageway with rollers. The rollers adjacent the inner passageway assist the wire in moving smoothly through the wire guide module as the shape of the inner passageway changing the direction of movement of the wire. A wire dispensing system having wire guide modules with rollers which change the direction of the wire while reducing damage to the wire.

Abstract: A wire dispensing system for dispensing wire from a wire coil in a drum to a welding site. The system includes a wire feeder mounted on the top of the drum above the wire coil.