Abstract: An improved liner for protecting an electrode wire within a body of a welding torch. The liner includes a liner retainer, which is removably coupled to a liner insert. The liner retainer is secured to a distal end of the welding torch and the liner insert is inserted and coupled to the liner retainer through a proximal end of the welding torch.

Abstract: Locking engagement connections between various components of a welding device can include tapered features having varied thread patterns and/or varied angles to ensure that the components remain tight during service. For example, locking engagement connections can be incorporated between a nozzle and a retaining head, a retaining head and a gooseneck, and/or a contact tip and a retaining head.

Abstract: An improved liner for protecting an electrode wire within a body of a welding torch. The liner includes a liner retainer, which is removably coupled to a liner insert. The liner retainer is secured to a distal end of the welding torch and the liner insert is inserted and coupled to the liner retainer through a proximal end of the welding torch.

Abstract: A robotic safety clutch that provides a wireless connection between the safety clutch and an robotic/automatic arm controller. The safety clutch includes a sensor for sensing a crash event and a radio frequency transmitter for transmitting a crash signal in response to the sensed crash event to a radio frequency receiver. The radio frequency receiver is connected to the robotic/automatic arm controller. Upon receiving the crash signal from the transmitter, the receiver sends a crash signal to the controller and in response to the crash signal, the controller shuts down all robotic/automatic functions.

Abstract: An electronic lock-on switch device for controlling the supply of electrode wire from a wire feeder to a welding torch. The device includes a housing that encloses a trigger circuit. The trigger circuit is connectable between the wire feeder and the welding torch for receiving a trigger signal from the torch indicating the trigger has been pressed and transmitting a feed signal to the wire feeder indicating the need to feed wire through the torch. The trigger circuit includes a switch mounted on the outside of the housing to allow the operator to select between normal and lock-on modes of operation. During the normal mode of operation, the wire feeder is activated and deactivated by simply pressing and releasing the trigger of the welding torch. The lock-on mode of operation allows the operator to switch between normal and lock-on modes of operation by simply varying the time in which the trigger is pressed.

Abstract: An arc welding torch for robotic applications having sensing capabilities to provide intelligent diagnostics monitoring of the welding process in real time. A plurality of modular sensors are integrated with the torch to provide real-time monitoring of wire speed, arc voltage, gas flow, seam-tracking, welding current temperature and contact tip wear. The torch includes a contact tip wear sensor for sensing the wearing of the tip during the welding process. The shielding gas flow is measured by a gas flow sensor mounted between the main housing and the gooseneck. A seam-tracking sensor is mounted on the outside of the housing to detect the position of the seam to be welded. The speed of the consumable electrode is measured by a wire speed sensor module. To ensure that operating temperatures of components near the arc region are within predetermined ranges for optimum performance of the torch, temperature sensors are mounted on the torch.

Abstract: A contact tip for use with a welding gun includes a tapered portion, a threaded portion, an extension portion and a gripping feature. The tip is elongated and has a first end and a second end. The tip also has a wire feed axis extending therethrough and an axial wire feed aperture extending therethrough. The tapered portion of the tip is at a second end of the tip and has a frustoconical shape. The threaded portion of the tip includes double threads and is adjacent the tapered portion. The extension portion of the tip is adjacent the threaded portion and extends to the first end of the tip. The gripping feature is disposed on the extension portion. The tapered portion serves as a retaining feature. The double threads provide additional thread length while allowing the tip to be quickly unthreaded for quick tip changes in use.

Abstract: A contact tip for use with a welding gun includes a tapered portion, a threaded portion, an extension portion and a gripping feature. The tip is elongated and has a first end and a second end. The tip also has a wire feed axis extending therethrough and an axial wire feed aperture extending therethrough. The tapered portion of the tip is at a second end of the tip and has a frustaconical shape. The threaded portion of the tip is adjacent the tapered portion. The extension portion of the tip is adjacent the threaded portion and extends to the first end of the tip. The gripping feature is disposed on the extension portion. The tapered portion serves as a retaining feature.

Abstract: An alignment system for a robotic gun assembly comprising a dual-keyed alignment system having a gun mounting arm comprising a keyway with a positive stop that corresponds to a key on the gun housing, and a second keyway with a positive stop within the gun housing that corresponds to a key on the robotic gooseneck.

Abstract: The present invention provides a break-away clutch for a robot end-of-arm tooling device for placement between a robot and a tooling device. The break-away clutch comprises a housing having a forward surface, a stud member, and a top plate having an underside facing surface. The housing has one end closed to form a cavity. The cavity holds a compression spring, and a piston that encapsulates the spring. The stud member has a ball end at one end resting on the piston and a distal end attached to the end-of-arm tooling device. The piston moves axially within the cavity and reacts to movement of the stud member. Notches located on the stud member, and pins located on the underside facing surface of the top plate translate rotational movement of the stud member to axial movement of the piston. A sensing device senses axial movement of the piston when the piston compresses the spring, and send a signal to the robot or end-of-arm tooling device if movement is beyond a predetermined amount.