Abstract: Embodiments of the present invention include a welding wire feeder enclosure, the enclosure including a front, a rear, a top, and a bottom forming a perimeter of the enclosure. The enclosure further includes opposing side openings separated by a width of the enclosure, each of the side openings being adapted for receiving a side panel. Particular embodiments further include a divider panel extending substantially between the front, rear, top, and bottom, and positioned along an intermediate portion of the width of the enclosure to divide an internal volume of the enclosure into a service side and a user side, the divider panel being formed monolithically with the front, rear, top, and bottom of the enclosure, the divider panel further including an integral spindle shaft location.

Abstract: Embodiments of the present invention include a welding wire feeder enclosure, the enclosure including a front, a rear, a top, and a bottom forming a perimeter of the enclosure. The enclosure further includes opposing side openings separated by a width of the enclosure, each of the side openings being adapted for receiving a side panel. Particular embodiments further include a divider panel extending substantially between the front, rear, top, and bottom, and positioned along an intermediate portion of the width of the enclosure to divide an internal volume of the enclosure into a service side and a user side, the divider panel being formed monolithically with the front, rear, top, and bottom of the enclosure, the divider panel further including an integral spindle shaft location.

Abstract: Portable welding wire feeders for providing welding wire and power to a welding torch, including a contactor with first and second copper or tellurium copper terminal studs, a conductive bridge member movable to electrically connect or isolate the terminals, and an actuator to control movement of the bridge according to a control signal. The contactor may also include a thermal sensor and the wire feeding apparatus may include a control circuit to provide the contactor control signal according to a temperature signal from the thermal sensor and according to a trigger signal from a welding torch.

Abstract: Welding wire feeders are disclosed for providing welding wire and electrical power to a welding torch in a welding system, in which an input is provided including an input connector integrated into a switching device of the wire feeder or coupled thereto directly or through a short cable. The input connector includes a cavity to receive wire from a power source cable with a clamping device being provided for selectively clamping the cable wire to the connector or releasing the wire therefrom using only simple tools.

Abstract: An electromechanical contactor device is disclosed for use in a wire feeder for an electric arc welder having a power source and a gun with a contact tip through which welding wire is fed and a weld cycle start trigger switch having a closed condition to initiate and hold a weld cycle and an open condition. The contactor device comprises a power inlet lead connected to the power source, an output lead connected to the contactor tip, one or more current branches between the input lead and the output lead with a mechanical contactor having an open condition and closed condition for opening and closing the branches. A solenoid operates the contactor device based upon the condition of the trigger switch, with a first position to close the contactor when said trigger switch is shifted from the open condition to the closed condition and to hold the contactor closed when the trigger switch is in the closed condition.

Abstract: An electro mechanical contactor device in a wire feeder for an electric arc welder having a power source and a gun with a contact tip through which welding wire is fed and a weld cycle start trigger switch having a closed condition to initiate and hold a weld cycle and an open condition. The contactor device comprises a power inlet lead connected to the power source, an output lead connected to the contactor tip, a plurality of current branches between the input lead and the output lead with a mechanical contactor having an open condition and closed condition for opening and closing each of the branches. A single solenoid operating the contactors in unison based upon the condition of the trigger switch, with a first position to close the contactors in unison when said trigger switch is shifted from the open condition to the closed condition and to hold the contactors closed when the trigger switch is in the closed condition.

Abstract: A cable coupler on a welder housing or wire feeder for conveniently connecting a cable to said welding housing or wire feeder. The cable coupler includes a coupler having a coupling jacket which contains an electrical coupling cavity having one or more one electrical connectors positioned therein and a coupling sleeve rotatably positioned at least partially about the coupling jacket. The coupling jacket is designed to be at least partially telescopically received in a cable connection sleeve of the cable. The electrical connector is designed to be electrically connected to a corresponding electrical connector in the cable connection sleeve when the coupling jacket is at least partially telescopically received in the cable connection sleeve.