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

Abstract: A wire guide, for a drive assembly of a wire feeding assembly, of a welding system, has an elongate body which has with an outer surface, a length, and first and second ends. An elongate bore extends along the length of, and through, the elongate body. An aperture extends through the elongate body, generally transverse to, and intersecting, the elongate bore. In some embodiments, the elongate body includes first and second body portions which can axially, laterally, and/or rotationally move with respect to each other. A generally arcuate recess can extend transversely into the outer surface of the elongate body, and can communicate with the aperture which extends through the elongate body, in a direction transverse to the elongate bore.

Abstract: A wire guide (16), for a drive assembly (56) of a wire feeding assembly (16), of a welding system (10), has an elongate body with an outer surface, a length, and first (296A) and second (296B) ends. An elongate bore (255) extends along the length of, and through, the elongate body. An aperture (265) extends through the elongate body, generally transverse to, and intersecting, the elongate bore (255). In preferred embodiments, at least one generally arcuate depression (260, 262) extends into the outer surface of the elongate body, communicating with the aperture (265) which extends through the elongate body, in a direction transverse to the elongate bore (255).

Abstract: A welding gun inlet for use with a welding gun power pin of a welding gun. The welding gun inlet includes an inlet body which has a first end and a second end and a tapered outer wall which generally tapers downwardly from a relatively larger diameter portion adjacent the first end to a relatively lesser diameter portion adjacent the second end. The welding gun inlet further includes an insertable member which extends outwardly from the inlet body. The insertable member has a length and defines a relatively constant cross-sectional diameter along at least a major portion of the length of the insertable member.

Abstract: A welding gun power pin for attaching a welding gun to a power block of a welding system. The welding gun power pin includes a generally cylindrical pin body, and insertion stop member, and a withdrawal stop member which defines a withdrawal stop member length dimension. A channel extends into the outer circumferential surface of the pin body, generally separates the pin body from the withdrawal stop member, and is adapted and configured to accept a generally rigid projection member therein, whereby to mechanically resist withdrawal of the welding gun power pin from the remainder of the welding system. The channel defines a channel width dimension which has a magnitude that is less than the magnitude of the withdrawal stop member length dimension.

Abstract: A power block for holding a welding gun power pin has a receiving structure which defines a bore which receives and holds a welding gun power pin. The power block further includes a projection movable between at least a first position and a second position. When the projection is in the first position, the projection extends at least partially into the receiving structure cavity. When the projection is in the second position, the projection generally does not extend into the receiving structure cavity. In some embodiments, the projection has a generally straight line distal edge. In other embodiments, the projection has a generally arcuate distal edge.

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.

Abstract: A welding gun power pin for attaching a welding gun to a power block of a welding system. The welding gun power pin includes a generally cylindrical pin body, and insertion stop member, and a withdrawal stop member which defines a withdrawal stop member length dimension. A channel extends into the outer circumferential surface of the pin body, generally separates the pin body from the withdrawal stop member, and is adapted and configured to accept a generally rigid projection member therein, whereby to mechanically resist withdrawal of the welding gun power pin from the remainder of the welding system. The channel defines a channel width dimension which has a magnitude that is less than the magnitude of the withdrawal stop member length dimension.

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 guide (16), for a drive assembly (56) of a wire feeding assembly (16), of a welding system (10), has an elongate body with an outer surface, a length, and first (296A) and second (296B) ends. An elongate bore (255) extends along the length of, and through, the elongate body. An aperture (265) extends through the elongate body, generally transverse to, and intersecting, the elongate bore (255). In preferred embodiments, at least one generally arcuate depression (260, 262) extends into the outer surface of the elongate body, communicating with the aperture (265) which extends through the elongate body, in a direction transverse to the elongate bore (255).

Abstract: A wire guide, for a drive assembly of a wire feeding assembly, of a welding system, has an elongate body which has with an outer surface, a length, and first and second ends. An elongate bore extends along the length of, and through, the elongate body. An aperture extends through the elongate body, generally transverse to, and intersecting, the elongate bore. In some embodiments, the elongate body includes first and second body portions which can axially, laterally, and/or rotationally move with respect to each other. A generally arcuate recess can extend transversely into the outer surface of the elongate body, and can communicate with the aperture which extends through the elongate body, in a direction transverse to the elongate bore.

Abstract: A power block for holding a welding gun power pin has receiving structure which defines a bore which receives and holds a welding gun power pin. The power block further includes a projection movable between at least a first position and a second position. When the projection is in the first position, the projection extends at least partially into the receiving structure cavity. When the projection is in the second position, the projection generally does not extend into the receiving structure cavity. In some embodiments, the projection has a generally straight line distal edge. In other embodiments, the projection has a generally arcuate distal edge.

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.

Abstract: A welding gun inlet for use with a welding gun power pin of a welding gun. The welding gun inlet includes an inlet body which has a first end and a second end and a tapered outer wall which generally tapers downwardly from a relatively larger diameter portion adjacent the first end to a relatively lesser diameter portion adjacent the second end. The welding gun inlet further includes an insertable member which extends outwardly from the inlet body. The insertable member has a length and defines a relatively constant cross-sectional diameter along at least a major portion of the length of the insertable member.

Abstract: A gas diffuser for a welding gun in which atmospheric air in the interior of the liner is substantially prevented from entering the contact tip hole. The gas diffuser includes a cradle having a hole and a section of a concave surface disposed around a periphery of the hole, and an outer peripheral body having a first axial bore on one side of the cradle and a second axial bore on the other side of the cradle. The outer peripheral body includes one or more generally axial slots, each slot having one end that opens into the first axial bore and another end that opens into the second axial bore. Each slot is open to the exterior of the diffuser along its length and is disposed radially outward of the cradle. The first and second axial bores communicate via the hole in the cradle and via the slots.

Abstract: A gas diffuser for a welding gun in which atmospheric air in the interior of the liner is substantially prevented from entering the contact tip hole. The gas diffuser comprises a cradle having a hole and a section of a concave surface disposed around a periphery of the hole, and an outer peripheral body having a first axial bore on one side of the cradle and a second axial bore on the other side of the cradle. The outer peripheral body comprises one or more generally axial slots, each slot having one end that opens into the first axial bore and another end that opens into the second axial bore. Each slot is open to the exterior of the diffuser along its length and is disposed radially outward of the cradle. The first and second axial bores communicate via the hole in the cradle and via the slots.

Abstract: A welding gun comprising: an electrically conductive gun body having a passageway; a head tube assembly having one end inserted in the passageway of the gun body; a rotation nut that retains the head tube assembly in the inserted state when the rotation nut is threadably coupled to the gun body; and an electrically insulative ring installed between a portion of the gun body and an electrically conductive part of the head tube assembly. The electrically conductive gun body has a frusto-conical inner peripheral surface that is in contact with a frusto-conical outer peripheral surface of the electrically insulative ring. The rotation nut comprises an electrically conductive part that is threadably engaged to the electrically conductive gun body and that is in electrical contact with the electrically conductive portion of the head tube assembly.

Abstract: A welding gun comprising: an electrically conductive gun body having a passageway; a head tube assembly having one end inserted in the passageway of the gun body; a rotation nut that retains the head tube assembly in the inserted state when the rotation nut is threadably coupled to the gun body; and an electrically insulative ring installed between a portion of the gun body and an electrically conductive part of the head tube assembly. The electrically conductive gun body has a frusto-conical inner peripheral surface that is in contact with a frusto-conical outer peripheral surface of the electrically insulative ring. The rotation nut comprises an electrically conductive part that is threadably engaged to the electrically conductive gun body and that is in electrical contact with the electrically conductive portion of the head tube assembly.

Abstract: The present invention is directed to an apparatus for securing a power cable from a power source to a wire feeder of a welding system. The wire feeder includes an inlet configured to receive a de-sheathed portion of the power cable. A frame includes at least one cavity and, preferably, a pair of cavities coaxial with respect to one another and orthogonal with respect to the inlet are provided. The first cavity has a securing mechanism such as a stud or setscrew disposed therein such that the securing mechanism engages a portion of the de-sheathed cable. The securing mechanism engages the power cable to lodge a portion of the power cable within the second cavity thereby creating a secure attachment of the power cable to the wire feeder.

Abstract: The present invention is directed to an apparatus for securing a power cable from a power source to a wire feeder of a welding system. The wire feeder includes an inlet configured to receive a de-sheathed portion of the power cable. A frame includes at least one cavity and, preferably, a pair of cavities coaxial with respect to one another and orthogonal with respect to the inlet are provided. The first cavity has a securing mechanism such as a stud or setscrew disposed therein such that the securing mechanism engages a portion of the de-sheathed cable. The securing mechanism engages the power cable to lodge a portion of the power cable within the second cavity thereby creating a secure attachment of the power cable to the wire feeder.