Abstract: A gripping device is disclosed for a set of pinch rollers used in a wire feeder that supplies a welding operation with a consumable welding wire. The welding wire passes between the pinch rollers whereby the pinch rollers engage the wire with a gripping force and incrementally rotate to control the outflow of the wire to the welding operation. The gripping device has a first member which is displaceable relative to a second member and a spring mechanism extending between the first and second members which has at least a first and a second spring modulus. The spring mechanism produces the gripping force as the first and the second members are displaced toward one another. The gripper urges one roller of the set of pinch rollers toward the other roller of the set to engage the wire and to apply the gripping force.

Abstract: A gripping device is disclosed for a set of pinch rollers used in a wire feeder that supplies a welding operation with a consumable welding wire. The welding wire passes between the pinch rollers whereby the pinch rollers engage the wire with a gripping force and incrementally rotate to control the outflow of the wire to the welding operation. The gripping device has a first member which is displaceable relative to a second member and a spring mechanism extending between the first and second members which has at least a first and a second spring modulus. The spring mechanism produces the gripping force as the first and the second members are displaced toward one another. The gripper urges one roller of the set of pinch rollers toward the other roller of the set to engage the wire and to apply the gripping force.

Abstract: An apparatus for feeding a wire. The apparatus includes at least one pair of rotatable rollers and at least one curved or curvable force-generating element. The at least one curved or curvable force-generating element is capable of applying a force via a proximal end of the at least one curved or curvable force-generating element to displace a first roller of the at least one pair of rotatable rollers towards a second roller of the at least one pair of the rotatable rollers to engage a wire there between. The apparatus further includes an adjustment mechanism operationally connected at a distal end of the at least one curved or curvable force-generating element to allow adjustment of the applied force.

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 invention is provided which comprises a welding carriage having a base, rear wheel assemblies disposed at one end of the base, a first front wheel assembly attachment member disposed on a second side of the base, and a first front wheel assembly configured to removably engage with the front wheel assembly attachment member to securely couple with the base. The welding carriage may also include a second front wheel assembly attachment member disposed on a second side of the base, and a second front wheel assembly configured to removably engage with at least the at least one front wheel assembly attachment member to securely couple with the base. The carriage may also include at least two welding attachment portions, where both welding attachment portions have the same cross-sectional characteristics.

Abstract: A modular portable welding wire feeder housed in a easily removable and interchangeable housing. The wire feeder includes a wire feeding module conveniently mounted inside of the housing. The housing is configured so that it may easily be removed from the wire feeing module, thereby allowing the housing to be easily replaced or exchanged as needed by the user.

Abstract: Welding wire feeders and a stick electrode holder capable of providing auxiliary electric power from a welding power source via an electrode cable to an auxiliary welding tool. A welding output of the welding power source may be switched between a regulated primary power and a regulated auxiliary power. An auxiliary welding tool, when connected to the welding wire feeder or the stick electrode holder, may use the regulated auxiliary power provided via the electrode cable when the regulated auxiliary power is selected.

Abstract: An invention is provided which comprises a welding carriage having a base, rear wheel assemblies disposed at one end of the base, a first front wheel assembly attachment member disposed on a second side of the base, and a first front wheel assembly configured to removably engage with the front wheel assembly attachment member to securely couple with the base. The welding carriage may also include a second front wheel assembly attachment member disposed on a second side of the base, and a second front wheel assembly configured to removably engage with at least the at least one front wheel assembly attachment member to securely couple with the base. The carriage may also include at least two welding attachment portions, where both welding attachment portions have the same cross-sectional characteristics.

Abstract: An invention is provided which comprises a tandem welding carriage having at least two welding carriages coupled to each other. Each of the welding carriages having a base, rear wheel assemblies disposed at one end of the base, and welding attachment portions. The two welding carriages are coupled to each other using a coupling member, and each welding carriage is carrying an arc welding device and/or spool to allow for tandem arc welding.

Abstract: A portable wire feeder for providing welding wire and welding current to a welding operation includes an input electrically connected to a power source. An output is electrically connected to the input to receive welding current delivered to the input from the power source and to provide the welding current and welding wire to the welding operation through a guide hose. A motorized wire feeding system includes a motor and a feed roll driven by the motor to direct the wire from a wire supply to the output for provision of the welding wire to the welding operation through the guide hose. Power for the motorized wire feeding system is drawn from the welding current passed from the input to the output. A grounding assembly nonattachably contacts a work piece of the welding operation to electrically ground the power drawn from the welding current directly to the work piece.

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 wire feeding mechanism for advancing a continuous length of wire along a pathway includes a housing having two roller supports each rotatable about a corresponding axis transverse to a wire pathway. The roller supports are on opposite sides of the pathway and are driveably engaged with each other. A drive roller is on each of the roller supports for rotation therewith. The drive roller includes an outer surface extending circumferentially about the corresponding axis. The outer surface defines a groove having an included angle of less than ninety degrees (90°). The drive roller on each of the roller supports compressively contacts a continuous length of wire between the roller supports such that the wire is advanced along the pathway in response to rotation of the drive rollers.

Abstract: A welding apparatus is provided for carrying a welding gun across or past a surface for making welds. The apparatus may include one or more rolling components, such as wheels for example, that do not substantially plastically deform as a result of contacting or being in close proximity to recently completed welds or preheated joints and provide adequate traction to move the apparatus across or past the surface. A portion of the contact surface of the rolling component may be configured with a given surface roughness to provide sufficient traction.

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: A wire feeding mechanism for advancing a continuous length of wire along a pathway includes a housing having two roller supports each rotatable about a corresponding axis transverse to a wire pathway. The roller supports are on opposite sides of the pathway and are driveably engaged with each other. A drive roller is on each of the roller supports for rotation therewith. The drive roller includes an outer surface extending circumferentially about the corresponding axis. The outer surface defines a groove having an included angle of less than ninety degrees (90°). The drive roller on each of the roller supports compressively contacts a continuous length of wire between the roller supports such that the wire is advanced along the pathway in response to rotation of the drive rollers.

Abstract: A lighter weight, more flexible coaxial welding cable assembly, and a system and method for constructing same. An embodiment of the coaxial welding cable assembly comprises a central electrical conductor length having a first cross-sectional area and a first insulating jacket surrounding the central electrical conductor length. The coaxial welding cable assembly also includes a plurality of peripheral electrical conductor lengths surrounding the insulated central electrical conductor length, where a total cross-sectional area of the plurality of peripheral electrical conductor lengths is approximately the same as the first cross-sectional area of the central electrical conductor length. The central electrical conductor length is electrically insulated from the plurality of peripheral electrical conductor lengths only by the first electrically insulating jacket.

Abstract: A portable wire feeder for providing welding wire and welding current to a welding operation includes an input electrically connected to a power source. An output is electrically connected to the input to receive welding current delivered to the input from the power source and to provide the welding current and welding wire to the welding operation through a guide hose. A motorized wire feeding system includes a motor and a feed roll driven by the motor to direct the wire from a wire supply to the output for provision of the welding wire to the welding operation through the guide hose. Power for the motorized wire feeding system is drawn from the welding current passed from the input to the output. A grounding assembly nonattachably contacts a work piece of the welding operation to electrically ground the power drawn from the welding current directly to the work piece.

Abstract: A gripping device is disclosed for a set of pinch rollers used in a wire feeder that supplies a welding operation with a consumable welding wire. The welding wire passes between the pinch rollers whereby the pinch rollers engage the wire with a gripping force and incrementally rotate to control the outflow of the wire to the welding operation. The gripping device has a first member which is displaceable relative to a second member and a spring mechanism extending between the first and second members which has at least a first and a second spring modulus. The spring mechanism produces the gripping force as the first and the second members are displaced toward one another. The gripper urges one roller of the set of pinch rollers toward the other roller of the set to engage the wire and to apply the gripping force.

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: A wire feeder for supplying consumable welding wire to a welding gun includes a housing and a wire advancing mechanism connected to the housing for paying wire from a wire spool to a welding gun. A storage tray is formed with the housing. A wire spool support is connected to the housing and rotatably supports the wire spool. The wire spool support includes a wire spool support tray, an elevated member extending from the wire spool support tray, and a spool retention member connected to the elevated member and rotatably supporting the wire spool.