Abstract: A welding system includes a power supply configured to generate a welding waveform. A wire feeder conducts the welding waveform to a wire electrode, and includes a drive motor that drives the wire electrode bidirectionally, a motor current sensor that senses a current level of the motor, and a controller that receives a current level signal from the motor current sensor and controls operations of the motor. A welding current sensor senses welding current level, and a welding voltage sensor senses welding voltage level, and the sensors are located with the power supply or the wire feeder. The controller is configured to determine a contact event between the wire electrode and a non-workpiece object based on the current level signal from the motor current sensor and one or both of the welding current level and the welding voltage level, and automatically retract the wire electrode upon determining the contact event.

Abstract: A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding system includes a power supply configured to generate a welding waveform. A wire feeder conducts the welding waveform to a wire electrode, and includes a drive motor that drives the wire electrode bidirectionally, a motor current sensor that senses a current level of the motor, and a controller that receives a current level signal from the motor current sensor and controls operations of the motor. A welding current sensor senses welding current level, and a welding voltage sensor senses welding voltage level, and the sensors are located with the power supply or the wire feeder. The controller is configured to determine a contact event between the wire electrode and a non-workpiece object based on the current level signal from the motor current sensor and one or both of the welding current level and the welding voltage level, and automatically retract the wire electrode upon determining the contact event.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll having a first annular groove, a second drive roll having a second annular groove, a first welding wire located between the drive rolls in the annular grooves, and a second welding wire located between the drive rolls in the annular grooves. A biasing member biases the first drive roll toward the second drive roll to force the first welding wire to contact the second welding wire. The first welding wire contacts each of a first sidewall portion of the first annular groove, a first sidewall portion of the second annular groove, and the second welding wire. The second welding wire contacts each of a second sidewall portion of the first annular groove, a second sidewall portion of the second annular groove, and the first welding wire. The drive rolls rotate in opposite directions thereby moving the welding wires through the wire drive system.

Abstract: Embodiments of welding machines and methods for switching between electrically isolated welding output studs. One embodiment of a welding machine includes multiple welding output studs, a work stud, a contactor circuit, touch sense circuitry, and a contactor controller. The contactor controller is configured to determine that electrical contact has occurred between a first welding output stud of the multiple welding output studs and the work stud via the touch sense circuitry. The contactor controller is also configured to deactivate welding output power to other welding output studs of the multiple welding output studs via the contactor circuit based on determining that the electrical contact has occurred. The contactor controller is further configured to activate welding output power to the first welding output stud via the contactor circuit after deactivating the other welding output studs based on determining that the electrical contact has occurred.

Abstract: A welding system includes a multi-process power supply, a TIG torch, and a TIG power pin for connecting the TIG torch to the multi-process power supply. The multi-process power supply has a power output connection for a MIG torch and a controller. The Controller is configured to command shielding gas and welding current to be provided to the power output connection, and the power output connection is configured to provide the shielding gas and the welding current to a MIG torch when the MIG torch is connected to the power output connection. The TIG power pin connects the TIG torch to the power output connection such that the power output connection is configured to provide the shielding gas and the welding current to the TIG torch. The controller is configured such that at least one of the shielding gas and the welding current is not provided to the TIG torch through the power output connection until a user engages a control member.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll having a first annular groove, a second drive roll having a second annular groove, a first welding wire located between the drive rolls in the annular grooves, and a second welding wire located between the drive rolls in the annular grooves. A biasing member biases the first drive roll toward the second drive roll to force the first welding wire to contact the second welding wire. The first welding wire contacts each of a first sidewall portion of the first annular groove, a first sidewall portion of the second annular groove, and the second welding wire. The second welding wire contacts each of a second sidewall portion of the first annular groove, a second sidewall portion of the second annular groove, and the first welding wire. The drive rolls rotate in opposite directions thereby moving the welding wires through the wire drive system.

Abstract: Systems and methods of the present invention are directed to welding systems having a welding power supply and wire feeder, where the power supply and wire feeder communicate over the welding power cables. In exemplary embodiments, the wire feeder communicates with the power supply over the welding cables using current draw pulses which are generated and recognized by the power supply. Similarly, the power supply generates voltage pulses which are transmitted over the welding power cables and recognized by the wire feeder.

Abstract: A welding system includes a multi-process power supply, a TIG torch, and a TIG power pin for connecting the TIG torch to the multi-process power supply. The multi-process power supply has a power output connection for a MIG torch and a controller. The Controller is configured to command shielding gas and welding current to be provided to the power output connection, and the power output connection is configured to provide the shielding gas and the welding current to a MIG torch when the MIG torch is connected to the power output connection. The TIG power pin connects the TIG torch to the power output connection such that the power output connection is configured to provide the shielding gas and the welding current to the TIG torch. The controller is configured such that at least one of the shielding gas and the welding current is not provided to the TIG torch through the power output connection until a user engages a control member.