Abstract: Disclosed example welding wire feeders include: a spool hub configured to hold a wire spool; a wire drive configured to feed wire from the wire spool; a spool brake configured to selectively resist rotation of the wire spool; and control circuitry configured to: control the spool brake to resist the rotation of the wire spool while the wire drive is not feeding the wire from the wire spool; and in response to an operator input, control the spool brake to reduce resistance to the rotation of the wire spool and control the wire drive to not feed the wire from the wire spool.

Abstract: A welding sled, comprising a support base comprising one or more attachment points for attachment of a wire supply support and attachment of a wire drive assembly; a plurality of rollers coupled to a bottom of the support base; and a brake configured to selectively brake the welding sled.

Abstract: Example wire spool hub assemblies include: a spindle configured to hold a wire spool; a spool rotation resistor positioned on the spindle to resist rotation of the wire spool on the spindle; and a resistance adjuster configured to selectively apply two or more rotation resistances via the spool rotation resistor based on two or more discrete positions of the resistance adjuster.

Abstract: A welding sled, comprising a support base comprising one or more attachment points for attachment of a wire supply support and attachment of a wire drive assembly; a plurality of rollers coupled to a bottom of the support base; and a brake configured to selectively brake the welding sled.

Abstract: A welding wire feeder including an alignment tongue and groove connection between a clamp arm and a welding drive assembly housing is provided. In certain embodiments, an alignment tongue extends from an end of the clamp arm opposite a pivot point about which the clamp arm rotates relative the assembly housing. A corresponding alignment groove may be formed in the assembly housing to receive the alignment tongue when the clamp arm is rotated such that a drive wheel mounted on the clamp arm contacts a drive wheel mounted on the assembly housing. In addition, a tensioner may be pivoted into a groove in the clamp arm to transfer a compressive force through the clamp arm, forcing the drive wheels together. The alignment tongue and groove may reduce lateral displacement of the clamp arm relative to the assembly housing that may be caused by a force transferred to the clamp arm as the tensioner is pivoted.

Abstract: A welding-type system includes a welding torch comprising a contact tip to provide an electrode wire. A secondary contact in electrical contact with the electrode wire, the secondary contact located along a length of the electrode wire and before the contact tip. Each of the contact tip and the secondary contact are connected to a welding-type power source. A current limiting device coupling located between the welding-type power source and the secondary contact and configured to limit a current at the secondary contact.

Abstract: Example wire spool hub assemblies include: a spindle configured to hold a wire spool; a spool rotation resistor positioned on the spindle to resist rotation of the wire spool on the spindle; and a resistance adjuster configured to selectively apply two or more rotation resistances via the spool rotation resistor based on two or more discrete positions of the resistance adjuster.

Abstract: A welding sled, comprising a support base comprising one or more attachment points for attachment of a wire supply support and attachment of a wire drive assembly; a plurality of rollers coupled to a bottom of the support base; and a brake configured to selectively brake the welding sled.

Abstract: Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop are disclosed. Example welding-type power supplies include a power converter configured to convert input power to output welding-type power to a remote device via a weld cable; a reference conductor connected between the power supply and the remote device; a voltage monitor configured to determine a first voltage between the weld cable and the reference conductor while substantially zero current is being conducted through the reference conductor; and a receiver circuit configured to receive a second voltage between the weld cable and the reference conductor from the remote device.

Abstract: Methods and apparatuses for welding remote power supply are disclosed. An example welding remote power supply includes a housing to house an electronic component. A connector secures an electrical cable to the housing, the electrical cable having at least one conductive wire and a sheathing. A conductive element is connected to the electronic component through the sheath and into contact with the conductive wire to electrically connect the conductive wire with the electronic component.

Abstract: A welding-type system includes a welding torch comprising a contact tip to provide an electrode wire. A secondary contact in electrical contact with the electrode wire, the secondary contact located along a length of the electrode wire and before the contact tip. Each of the contact tip and the secondary contact are connected to a welding-type power source. A current limiting device coupling located between the welding-type power source and the secondary contact and configured to limit a current at the secondary contact.

Abstract: A welding wire feeder including an alignment tongue and groove connection between a clamp arm and a welding drive assembly housing is provided. In certain embodiments, an alignment tongue extends from an end of the clamp arm opposite a pivot point about which the clamp arm rotates relative the assembly housing. A corresponding alignment groove may be formed in the assembly housing to receive the alignment tongue when the clamp arm is rotated such that a drive wheel mounted on the clamp arm contacts a drive wheel mounted on the assembly housing. In addition, a tensioner may be pivoted into a groove in the clamp arm to transfer a compressive force through the clamp arm, forcing the drive wheels together. The alignment tongue and groove may reduce lateral displacement of the clamp arm relative to the assembly housing that may be caused by a force transferred to the clamp arm as the tensioner is pivoted.

Abstract: A welding wire feeder including an alignment tongue and groove connection between a clamp arm and a welding drive assembly housing is provided. In certain embodiments, an alignment tongue extends from an end of the clamp arm opposite a pivot point about which the clamp arm rotates relative the assembly housing. A corresponding alignment groove may be formed in the assembly housing to receive the alignment tongue when the clamp arm is rotated such that a drive wheel mounted on the clamp arm contacts a drive wheel mounted on the assembly housing. In addition, a tensioner may be pivoted into a groove in the clamp arm to transfer a compressive force through the clamp arm, forcing the drive wheels together. The alignment tongue and groove may reduce lateral displacement of the clamp arm relative to the assembly housing that may be caused by a force transferred to the clamp arm as the tensioner is pivoted.

Abstract: Welding power supplies, wire feeders, and systems to measure a weld cable voltage drop are disclosed. Example welding-type power supplies include a power converter configured to convert input power to output welding-type power to a remote device via a weld cable; a reference conductor connected between the power supply and the remote device; a voltage monitor configured to determine a first voltage between the weld cable and the reference conductor while substantially zero current is being conducted through the reference conductor; and a receiver circuit configured to receive a second voltage between the weld cable and the reference conductor from the remote device.

Abstract: Methods and apparatuses for welding remote power supply are disclosed. An example welding remote power supply includes a housing to house an electronic component. A connector secures an electrical cable to the housing, the electrical cable having at least one conductive wire and a sheathing. A conductive element is connected to the electronic component through the sheath and into contact with the conductive wire to electrically connect the conductive wire with the electronic component.

Abstract: A wire guide for use in a welding wire feeder is provided. The wire guide includes two guide surfaces spaced from one another to define an opening through which welding wire is directed from a spool to a wire drive assembly of the wire feeder. The wire guide may also include a side flange extending from an outboard position of the wire guide to maintain the wire within a desired region of the wire drive assembly, such as a space formed by grooves along rollers of the wire drive assembly. The side flange may be formed integrally with an outboard guide surface of the wire guide. The guide surfaces and the side flange may be formed integrally into a one-piece wire guide structure.

Abstract: A running gear system for a portable wire feeder case is disclosed that includes a plurality of wheel assemblies configured to rotate between a first retracted position and a first deployed position, a handle configured to extend between a second retracted position and a second deployed position, and a retractable support, wherein the plurality of wheel assemblies and the retractable support are configured to cooperatively support the portable wire feeder case in a horizontal orientation.

Abstract: A welding torch is provided that includes a motorized arrangement for advancing continuous electrode wires during welding. The torch has a pair of rollers that contact the electrode wire to force it through the torch during welding. A force adjustment selector is provided in the torch handle that allows the operator to alter the force or pressure applied to the electrode wire. Markings on the handle, or stops provided between the selector and the handle allow for easy adjustment and verification of the proper pressure or force applied for specific types of electrode wires.

Abstract: A wire guide for use in a welding wire feeder is provided. The wire guide includes two guide surfaces spaced from one another to define an opening through which welding wire is directed from a spool to a wire drive assembly of the wire feeder. The wire guide may also include a side flange extending from an outboard position of the wire guide to maintain the wire within a desired region of the wire drive assembly, such as a space formed by grooves along rollers of the wire drive assembly. The side flange may be formed integrally with an outboard guide surface of the wire guide. The guide surfaces and the side flange may be formed integrally into a one-piece wire guide structure.

Abstract: A welding wire feeder including an alignment tongue and groove connection between a clamp arm and a welding drive assembly housing is provided. In certain embodiments, an alignment tongue extends from an end of the clamp arm opposite a pivot point about which the clamp arm rotates relative the assembly housing. A corresponding alignment groove may be formed in the assembly housing to receive the alignment tongue when the clamp arm is rotated such that a drive wheel mounted on the clamp arm contacts a drive wheel mounted on the assembly housing. In addition, a tensioner may be pivoted into a groove in the clamp arm to transfer a compressive force through the clamp arm, forcing the drive wheels together. The alignment tongue and groove may reduce lateral displacement of the clamp arm relative to the assembly housing that may be caused by a force transferred to the clamp arm as the tensioner is pivoted.