Abstract: A method and system for detecting a welding gas leak is provided. One welding power supply includes a gas valve configured to control the flow of shielding gas to a welding device through a gas line. The welding power supply also includes a sensor coupled to the gas line and configured to detect a parameter of the shielding gas. The welding power supply includes control circuitry coupled to the gas valve and to the sensor, and configured to control the operation of the gas valve, and to receive device value representative of the detected parameter. The control circuitry is further configured to determine a leak test result based upon the parameter value, and to provide an operator indicator of the leak test result.

Abstract: A weld electrical and gas connector with sealed gas flow is provided. In an exemplary embodiment, a welding cable connector system includes a male connector having a conductive body for conveying welding power. The male connector includes a sealed passageway disposed coaxially of the conductive body for conveying shielding gas, and a gas sealing valve configured to seat to stop flow of shielding gas when the male connector is not engaged. The system also includes a female connector having a conductive body for conveying welding power. The female connector includes a sealed passageway disposed coaxially of the conductive body for conveying shielding gas, and a gas sealing valve configured to seat to stop flow of shielding gas when the female connector is not engaged. The male and female connectors are mutually engageable to conduct welding power and shielding gas therethrough.

Abstract: A cable assembly with strain relief for providing welding control is provided. One welding control cable assembly includes a cable having a plurality of conductors configured to convey data and/or power in an insulative jacket. The cable assembly also includes a retainer bound to an outer surface of the insulative jacket adjacent to an end of the cable and a connector assembly having a plurality of connector elements in a housing. Each of the connector elements is terminated to a respective one of the conductors. The housing is disposed adjacent to the retainer. The assembly includes an overmolded shell disposed over the retainer and at least a portion of the connector assembly. At least the insulative jacket, the retainer and the overmolded shell cooperate to resist stress on the conductors by axial tensile forces placed on the connector assembly.

Abstract: An external support structure for a welding power supply includes a cage-like assembly that is configured to receive and at least partially surround the welding power supply. The cage-like assembly includes fastening points allowing for securement of the welding power supply within the assembly. The assembly further includes stacking members to permit stacking of the assembly with a self-similar structure.

Abstract: Embodiments of a welding system include a compact wire feeder adapted to feed welding wire having a diameter up to approximately 5/64 inches disposed on a wire spool having an outer diameter of approximately 8 inches. The compact wire feeder may include a housing, a spool mounting hub disposed in the housing and adapted to receive the wire spool, and a wire drive assembly having a motor adapted to apply an output torque to a shaft of a gearbox to drive the welding wire from the welding spool to a welding torch.