Abstract: Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.

Abstract: A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.

Abstract: A method and apparatus for providing welding type power, including a power and control circuit is disclosed. The power circuit provides welding, control and aux power. The control and aux power are provided with a transformer, and secondary windings for control and aux power are wound on a single bobbin, with a winding separator separating them. Air vents, which can be formed by fins on the bobbin or separator allow cooling of the inner winding.

Abstract: A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Abstract: A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.

Abstract: A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Abstract: Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.

Abstract: A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.

Abstract: A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Abstract: A wire feeder comprises a motor and drive roll assembly. The motor and drive roll assembly comprises a base assembly having a left hand side and a right hand side. A first locating mechanism is on the right hand side and a second locating mechanism is on the left hand side. Modules, such as inlet or outlet guides can be located and mounted, preferably on either side. Each module preferably includes an additional locating mechanism to allow an additional module to be located by the additional locating mechanism. The locating mechanisms are preferably of the same design, and preferably each includes at least two holes with a locator pin disposed in each hole, and each module being located includes at least locating holes to receive the locator pins.

Abstract: A drive roll carrier is provided for use with a wire feeder for a welder that includes a hub that can be rotated by a gear and that may include at least one lug that extends longitudinally along and radially out from the hub and at least one retainer that extends from an outer surface of the hub. The retainer may be fixed in a longitudinal direction with respect to the hub and may be movable in a radial direction for allowing mounting of a drive roll onto the hub. An outer end of the lug may include an alignment segment that has a different profile shape than the rest of the lug to facilitate alignment of a mounting groove of the drive roll with the lug.

Abstract: A method and apparatus for providing welding type power, including a power and control circuit is disclosed. The power circuit provides welding, control and aux power. The control and aux power are provided with a transformer, and secondary windings for control and aux power are wound on a single bobbin, with a winding separator separating them. Air vents, which can be formed by fins on the bobbin or separator allow cooling of the inner winding.

Abstract: A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.

Abstract: A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Abstract: A wire feeder comprises a motor and drive roll assembly. The motor and drive roll assembly comprises a base assembly having a left hand side and a right hand side. A first locating mechanism is on the right hand side and a second locating mechanism is on the left hand side. Modules, such as inlet or outlet guides can be located and mounted, preferably on either side. Each module preferably includes an additional locating mechanism to allow an additional module to be located by the additional locating mechanism. The locating mechanisms are preferably of the same design, and preferably each includes at least two holes with a locator pin disposed in each hole, and each module being located includes at least locating holes to receive the locator pins.

Abstract: A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Abstract: A drive roll carrier is provided for use with a wire feeder for a welder that includes a hub that can be rotated by a gear and that may include at least one lug that extends longitudinally along and radially out from the hub and at least one retainer that extends from an outer surface of the hub. The retainer may be fixed in a longitudinal direction with respect to the hub and may be movable in a radial direction for allowing mounting of a drive roll onto the hub. An outer end of the lug may include an alignment segment that has a different profile shape than the rest of the lug to facilitate alignment of a mounting groove of the drive roll with the lug.

Abstract: A wire guide for use in a welding wire feeder is provided. The wire guide may consist of a pair of vertical pins mounted to a wire drive assembly to form a slit through which welding wire is guided toward a set of drive rolls. Another embodiment may consist of a generally conical piece with oblong entrance and exit ends mounted to the wire drive assembly.

Abstract: A drive roll release mechanism is rotatable about an axis of rotation and includes a drive roll carrier body having a carrier body sidewall adapted and configured to accept a drive roll thereon. The drive roll release mechanism further includes an actuator in sliding communication with the carrier body. A user depresses the actuator to correspondingly realize at least a partial release of a drive roll, which is removably mounted to the drive roll release mechanism, from the carrier body, enabling facile removal of the drive roll from the drive roll release mechanism.

Abstract: A wire pinch force mechanism has a drive assembly which includes at least a first drive roll and a second drive roll adapted and configured to drive a weld wire. The pinch force mechanism further includes a cover movable between a first relatively open position and a second relatively closed position; and a force converter, mounted to the cover, which communicates with and applies an adjustable force to the drive assembly.