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: A contactor device used in a wire-feeder employed in a welding system is disclosed. The contactor uses oversized nuts, increased torque and surface features to increase the heat dissipation of the contactor. This solution is an economical way of increasing heat dissipation to extend the life of contactors that are subject to failure due to heating and increased internal resistance.

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 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: A contactor device used in a wire-feeder employed in a welding system is disclosed. The contactor uses oversized nuts, increased torque and surface features to increase the heat dissipation of the contactor. This solution is an economical way of increasing heat dissipation to extend the life of contactors that are subject to failure due to heating and increased internal resistance.

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: 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 cable coupler on a welder housing or wire feeder for conveniently connecting a cable to said welding housing or wire feeder. The cable coupler includes a coupler having a coupling jacket which contains an electrical coupling cavity having one or more one electrical connectors positioned therein and a coupling sleeve rotatably positioned at least partially about the coupling jacket. The coupling jacket is designed to be at least partially telescopically received in a cable connection sleeve of the cable. The electrical connector is designed to be electrically connected to a corresponding electrical connector in the cable connection sleeve when the coupling jacket is at least partially telescopically received in the cable connection sleeve.

Abstract: A mounting assembly for a plurality of bipolar electrical components connected between two generally parallel electrical supports, each bipolar electrical component having a lower base terminal fixedly mounted to the first electrical support and a generally flat upper terminal having a random angular orientation about the central axis of the electrical components, an electrically conducting coupler which telescopically receives the upper terminal of the component to form a rigid electrical connection between the coupler and an electrical component at one end of the coupler and the other end of the coupler is electrically connected to the second electrical support.