Abstract: A wire level gauge for indicating the level of wire in a wire storage container and a method for determining the level of wire in a wire storage container using the wire level gauge. The wire level gauge has a level indicator with a magnet which is slidably movable on a measuring bar. The level indicator moves on the measuring bar and follows a leading edge of the wire in the wire storage container as the wire is dispensed from the wire storage container.

Abstract: A welding system having a welding gun with a contact tip having an bore extending therethrough and a consumable weld wire. The cross-sectional shape of the bore of the contact tip being is essentially identical to the cross-sectional shape of the weld wire. The bore having an essentially elliptical cross-sectional shape and the weld wire having an essentially 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 drum lifter for lifting and moving empty and full chimed and unchimed drums. The lifter includes a cross member with grippers at each end. The grippers include a cam block with a cam rotatably mounted in the cam block.

Abstract: A welding system having a welding gun with a contact tip having an bore extending therethrough and a consumable weld wire. The cross-sectional shape of the bore of the contact tip being is essentially identical to the cross-sectional shape of the weld wire. The bore having an essentially elliptical cross-sectional shape and the weld wire having an essentially elliptical cross-sectional shape.

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

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.

Abstract: A wire dispensing system for continuously dispensing wire from wire coils to a welding site. The system includes a wire feeder mounted above the wire coils on a frame and a wire transfer arm which moves between the wire coils as one wire coil is depleted and the other wire coil is started.

Abstract: A controller for controlling the dispensing of wire from a reel of wire positioned within a container. The wire is dispensed from one end of the reel with the other end of the reel sitting on the bottom of the container. The controller has a main body member in the shape of a flat ring sized to rest within the container on the one end of the reel, the ring having concentric, circular, inner and outer edges. Flexible, wire guide flaps are on the inner edge of the ring, the guide flaps extending radially inwardly. Each guide flap has the general shape of a shallow triangle with the apex of the triangle farthest from the ring and the base of the triangle adjacent and integral with the ring.

Abstract: A dereeler for welding wire capable of dispensing wire from very heavy loaded reels wherein the reel may be rolled upon the reel spool peripheries into the dereeler and manually raised to a reel rotatable position. A carriage upon which the cradles supporting the reel are mounted is supported on a frame by a linkage system wherein pivoting of the carriage between reel loading and unloading positions permits the reel axle to be received within the cradles while the reel spools are supported on the floor, and pivoting of the carriage on the frame lifts the reel axle supported in the cradles from the supporting floor surface permitting rotation of the reel for wire dispensing purposes.

Abstract: A portable feeder for welding wire used to charge a welding wire guide system with a new coil of wire upon depletion of the previous welding wire coil. A casing includes a drive roller driven by a portable drill or the like, and a backup roller movably mounted upon the casing squeezes the welding wire passing through the casing between the rollers rapidly feeding the welding wire into guides formed on the casing in alignment with the wire guide system.

Abstract: Apparatus for monitoring manual arc welding procedures for providing to the welder real-time monitoring of the welding characteristics to achieve optimum welds. The voltage and current conditions of the welding arc are instantly transferred within the visual range of the helmet wearing operator by the use of lights, illuminated bar graphs, light projections, illuminated see-through displays, or the like, located in proximity to the helmet viewing window wherein, through such monitoring, the operator is constantly aware of the arc conditions during welding.

Abstract: A wire dispenser for dispensing coiled wire, such as welding wire, wherein the dispenser uses a wire guiding arm which rotates about the spool upper flange. The wire guide arm is mounted upon a vertical column supported by the spool end flange through a base plate concentrically located upon the spool flange. Selectively usable mounting structure defined on the base plate permits the dispenser to be used with spool end flanges having different sizes of hole dimensions and a cam type locking detent mounted upon the base plate firmly locks the base plate with respect to the spool flange. The wire guiding structure mounted upon the column includes a flexible tube permitting the wire guide to be most efficiently related to various sizes of wire coils and an adjustable arm supporting the flexible tube permits operators of ordinary skill to readily accommodate the dispenser to various sizes of spools.

Abstract: Apparatus for dispensing wire from a spool, such as welding wire, wherein the spool axis is vertically oriented and the spool includes end flanges confining the wire coil. A rotatable wire dispensing arm is mounted upon a base inserted in a hole within the upper spool flange and a friction brake interposed between the base and arm controls the rate of arm rotation. An extension in the form of a cam is formed upon the base to selectively increase the friction between the base and flange hole to prevent base rotation, and the dispensing arm includes a tube internally reinforced by a coiled wear sleeve while the entrance end of the wear sleeve is provided with a hard, wear resistant ceramic ring to reduce wear.

Abstract: A combination work supporting table and computer controlled robot wherein, preferably, a rotatable index table includes a concentric column having a computer controlled robot mounted upon the column outer end in spaced relationship to the table work supporting surface. A computerized robot controller controls both the robot and the rotation of the index table permitting an extensive range of robot movement over a large work area in a concise space.