Abstract: Systems and methods are provided for utilizing wearable wire feeders. An example welding-type system may include a wire feeder device configured for operation in conjunction with a welding-type power supply unit and a welding-type torch, with the wire feeder device being a physically separate component from both of the welding-type power supply unit and the welding-type torch, and with the wire feeder device including, at least, a wire source configured to provide electrode wire, and a wire feeding mechanism configured to feed the electrode wire from the wire source. The wire feeder device may be powered by the welding-type power supply unit, and the wire feeder device may be configured to feed the electrode wire to the welding-type torch.

Abstract: Systems and methods are provided for utilizing in-line wire feeders. A welding-type system may include an in-line wire feeder device configured to feed electrode wire from a wire source. The in-line wire feeder device may include an in-line wire feeding mechanism, may be a physically separate component from both of a second wire feeder device and a welding-type torch, and may be connected in series with the second wire feeder device. The in-line wire feeder device may control feeding of the electrode wire from a wire source, with the controlling including causing the second wire feeder device to feed the electrode wire from the wire source until the electrode wire reaches the in-line wire feeding mechanism, and then afterwards deactivating at least a feeding function of the second wire feeder device, and causing the in-line wire feeding mechanism to take over feeding of the electrode wire from the wire source.

Abstract: A drive roll is disclosed that is useable in a wire feeder for advancing a wire. The drive roll includes a first side, a second side offset from the first side, and an annular surface between the first side and the second side. An annular groove is formed in the annular surface and defines an engagement surface. Pluralities of lands are spaced along the engagement surface and pluralities of notches are formed in the engagement surface for engaging and advancing the wire. An engagement ratio is defined between the total land area of the plurality of lands and the total notch area of the plurality of notches calculated at the engagement surface. The engagement ratio defines a drive roll that accurately engages and advances the wire over a longer period of use.

Abstract: A drive roll is disclosed that is useable in a wire feeder for advancing a wire. The drive roll includes a first side, a second side offset from the first side, and an annular surface between the first side and the second side. An annular groove is formed in the annular surface and defines an engagement surface. Pluralities of lands are spaced along the engagement surface and pluralities of notches are formed in the engagement surface for engaging and advancing the wire. An engagement ratio is defined between the total land area of the plurality of lands and the total notch area of the plurality of notches calculated at the engagement surface. The engagement ratio defines a drive roll that accurately engages and advances the wire over a longer period of use.

Abstract: A drive roll (180) adapted and configured to feed weld wire (54) comprises first and second opposing sides (238, 239) and an outer body surface (290). The outer body surface (290) comprises a base body surface (BBS), and at least one elevated wire interface (244) extending outwardly from and along at least a major portion of the base body surface. The elevated wire interface (244) can rotationally drivingly engage the weld wire (54), which enables the drive roll (180) to advance the weld wire (54) along e.g. a desired path of travel such as to a welding arc.