Abstract: A welding gun is provided that includes a handle having forward and rear end portions and having a first passageway formed therethrough. A cable support tube having forward and rear end portions and a second passageway formed therethrough is secured to the handle at the forward end portion. A welding cable having a forward end portion and a rear end portion connected to a rear connector assembly extends from the rear end portion through the first and second passageways of the handle and the cable support tube to the forward end portion disposed within the forward end portion of the cable support tube.

Abstract: An attachment device for use in connecting a conductor tube to a handle of a welding gun is provided that includes an adapter disposed proximate the handle of the welding gun, wherein the adapter defines a plurality of radially spaced receiving portions. A conductor tube is disposed adjacent the adapter, and the conductor tube defines at least one extension disposed near a proximal end portion of the conductor tube. The plurality of radially spaced receiving portions are adapted for engagement by the extension of the conductor tube such that the conductor tube can be repositioned relative to the handle of the welding gun.

Abstract: A conductor tube for use in a welding gun, and preferably a MIG welding gun, is provided that includes a plurality of flex joints. The flex joints include a body defining a proximal end portion and a distal end portion, a cap secured to the proximal end portion of the body, and an extension mounted within the distal end portion of the body, the extension being repositionable within the body. The body, the extension, and the cap are adapted for attachment to each other and to adjacent components of the welding gun. Additionally, a conductor tube for use in a welding gun includes a plurality of thermally and electrically conductive elements secured to each other and extending along a length of the conductor tube, wherein the elements are independently repositionable relative to each other.

Abstract: A welding contact tip and diffuser assembly for use in a welding apparatus. The assembly includes an electrically conductive contact tip having a tapered exterior surface, a diffuser having a cavity with a tapered interior surface, and a releasable connection for holding the contact tip in the diffuser. The connection includes at least one detent element in either the diffuser or the contact tip, at least one recess forming a ramp in the other of the diffuser or contact tip, and at least one spring. The spring biases the detent element into the recess and against the ramp to generate an axial force against the ramp. The axial force tends to urge the tapered surfaces of the contact tip and diffuser into contact with one another.

Abstract: A welding contact tip and diffuser assembly for use in a welding apparatus. The assembly includes an electrically conductive contact tip having a tapered exterior surface, a diffuser having a cavity with a tapered interior surface, and a releasable connection for holding the contact tip in the diffuser. The connection includes at least one detent element in either the diffuser or the contact tip, at least one recess forming a ramp in the other of the diffuser or contact tip, and at least one spring. The spring biases the detent element into the recess and against the ramp to generate an axial force against the ramp. The axial force tends to urge the tapered surfaces of the contact tip and diffuser into contact with one another.

Abstract: A MIG welding torch reconditioning apparatus has a pneumatic supply line, vent means and a mechanical transmission shaft. The pneumatic supply line supplies air to the vent means for venting a directed debris-scattering air-flow against the transmission shaft proximal to exposed seals thereon. In another aspect, the apparatus has an in-line, direct-drive arrangement of a motor, a mechanical transmission shaft, and chuck means for receiving a reaming tool. Pneumatic lift means lifts the direct-drive arrangement into reaming tool engagement with the gas shield of a torch wherein the tool is operable to remove at least some of any back-splash deposits laid down on interior surfaces of the gas shield. A clamp is also provided for engaging a cylindrical body, such as a torch. The clamp includes a pair of generally orthogonally-offset faces of a “V”-block and respective gripping surfaces on gripping surface members of a pair of opposed jaws.

Abstract: A MIG welding torch reconditioning apparatus has a pneumatic supply line, vent means and a mechanical transmission shaft. The pneumatic supply line supplies air to the vent means for venting a directed debris-scattering air-flow against the transmission shaft proximal to exposed seals thereon. In another aspect, the apparatus has an in-line, direct-drive arrangement of a motor, a mechanical transmission shaft, and chuck means for receiving a reaming tool. Pneumatic lift means lifts the direct-drive arrangement into reaming tool engagement with the gas shield of a torch wherein the tool is operable to remove at least some of any back-splash deposits laid down on interior surfaces of the gas shield. A clamp is also provided for engaging a cylindrical body, such as a torch. The clamp includes a pair of generally orthogonally-offset faces of a “V”-block and respective gripping surfaces on gripping surface members of a pair of opposed jaws.

Abstract: A method and apparatus for reconditioning a MIG welding torch of the type having a gas shield through which gas is exhausted from the torch comprises inserting a reaming tool within an opening of the gas shield. The reaming tool is moved relative to the gas shield within the opening into contact with deposits adhered to the gas shield within the opening. An impact force is applied through the reaming tool against the deposits in the event that movement of the reaming tool relative to the gas shield is substantially inhibited by any of the deposits.

Abstract: A torch for cutting, gouging or welding metal including a body having a central longitudinal axis for connection to sources of pressurized gas and electrical potential and a swivel housing threadably connected to the body for rotation relative to the body about the axis and a tubular handle around the body and the swivel housing. The handle has front and rear sections manually relatively rotatable. The front section and swivel housing are rotatable as a unit, and the rear section and body are rotatable as a unit so that rotation of one section relative to the other effects rotation of the swivel housing relative to the body. The torch includes a head forward of the swivel housing having an opening for holding an electrode and includes an elongate unitary swivel member having a forward end non-rotatably attached to the head and a rearward swivel end disposed in an opening of the swivel housing.

Abstract: A strain relief assembly for reducing bending of a welding cable used to deliver welding wire, welding gas and electricity from a welding machine to a welding gun for welding a workpiece. The assembly includes first and second strain relief elements surrounding and extending along the welding cable for supporting and providing strain relief to the cable. The assembly also includes a connector for attaching the strain relief elements to at least one of the machine and the gun. The first strain relief element extends a first distance from the connector for supporting the cable. Thus, the first element reduces bending of a first portion of the cable positioned inside the first strain relief element. The second strain relief element extends a second distance, which is greater than the first distance, from the connector for supporting the cable and the first strain relief element.

Abstract: A gas lens assembly for an arc welding torch includes a lens body having a rearward end and a forward end, a passage through the lens body from its forward end to its rearward end for receiving an electrode therethrough and for permitting flow of an inert gas in a forward direction in the passage. A lens housing is secured to the lens body and defines a chamber around a forward end portion of the lens body. One or more openings in the forward end portion of the lens body enable the inert gas to flow from the passage into the chamber. The gas lens assembly further includes a flow control device associated with the housing through which said inert gas is adapted to flow in a forward direction. The flow control device controls the flow of the inert gas therethrough so that the gas exists the flow control device as a laminar stream of gas moving in a forward direction. The laminar stream is adapted to blanket a weld puddle during a welding operation on a workpiece.

Abstract: A welding gun assembly including a contact tip and gas diffuser having increased electrical conductivity and heat dissipation and a spool gun assembly having a rotatable and articulatable conductor tube mounted on the handle member thereof and a smoke gun assembly with a manually adjustable vacuum control member on the handle member and wherein the handle member conforms to the hand of the operator and includes an elongate trigger member thereon.

Abstract: Contact tips and diffusers, known as consumables, for MIG welding guns have a combined increase in mass over the prior art. The larger combined mass of the contact tips and diffusers, coupled with a three point thermal and electrical engagement, increase the life of the tips by a factor of between 2 and 6 times the prior art. The contact tip and diffuser engage; i) between a circumferential shoulder of the contact tip and the end of the circumferential opening of the lower interior chamber of the gas diffuser; ii) between the protrusion of the gas diffuser and a point on the circumferential channel of the contact tip; and iii) between a line on the contact tip opposite the protrusion of the gas diffuser and a line on an inner surface of the second interior chamber of the gas diffuser opposite the protrusion. A cam replaces prior art threads.

Abstract: The present invention includes several features which can be used alone or in combination. The three (3) primary features are: 1) an ergonomically designed welding gun; 2) a quick disconnect cable assembly, and 3) an improved contact tip and diffuser.The ergonomic design for the welding gun includes one or more of the following features: a) the conductor tube can be rotated 360.degree. about the centerline of the handle by the welder without resort to tools or disassembly of the gun; b) the conductor tube can be articulated 15.degree. up or down, side to side, without resort to tools or disassembly of the gun; c) the rear portion of the handle includes a gentle curve of approximately 10.degree. off the centerline to facility gripping by the operator; d) the handle operator to actuate the gun while gripping same either at the rear portion of the handle of the front portion of the handle.

Abstract: A breakaway mount connects a tool such as a welding torch with a robot or other automated machine. The mount can fully separate and detach from a baseplate in the event of a collision between the tool and the workpiece. The pneumatically operated mount is reassembled with the baseplate in a two-step procedure which allows the operator to move his fingers and hands away from the apparatus to avoid injury when the components are fully assembled. The breakaway mount can include a wrist joint which swivels back and forth in response to a collision between the tool and the workpiece. The apparatus can also be affixed with sensors to detect partial or complete detachment between the mount and the baseplate. The sensors shut down the robot or other automatic machinery in the event of partial or complete detachment. A second series of sensors can also be added to detect the movement in the wrist joint to likewise shut down the machinery.

Abstract: A liquid cooled welding gun assembly is adapted to be operatively connected to a power, gas, and weld wire feed mechanism through a cable assembly and a connector assembly. The welding gun assembly includes a front connector block and the connector assembly includes a rear connector block. Power, gas and cooling liquid hoses are contained within the cable assembly and intercommunicate the connector block of the welding gun assembly with the rear connector block. The welding gun assembly includes a liquid cooled nozzle assembly. In an alternative embodiment, a nozzle of the nozzle assembly has an internal cooling passage therein. The nozzle assembly includes alternative diffusers having longitudinally directed gas flow passages therein. A hose coupling assembly is provided for facilitating connecting and disconnecting the various power, gas and liquid hoses from the conductor blocks.

Abstract: A connector assembly includes first and second connectors which may be coupled by advancing a connector post on the first connector into a corresponding recess on the second connector. The assembly may then be fully engaged by 180.degree. rotation of one of the connectors about a longitudinal axis. Indicia on the connectors enable an operator to quickly ascertain whether the assembly is in engaged or disengaged position.

Abstract: A welding gun apparatus to supply welding wire, electrical power, and shielding gas to a working area includes a connector plug with a conduit stop therein. The conduit stop is fittedly received within a bore in the connector plug and is of unitary one-piece construction so as to provide a fluid-tight fit therewith.

Abstract: In a welding gun apparatus, an improved electrical power conductor assembly in which electrical conduit wire may be readily secured to a cable connector body while the structural integrity of the conduit wire is maintained. Conduit wire is fastened to the connector body by means of an axially movable connector sleeve which secures the wire against a tapered mandrel on the connector body. A pressure nut threadably adapted to the connector body controls the axial position of the connector sleeve.