Abstract: Apparatuses, systems, and/or methods for securing and unsecuring a wire feeder in an automatic welding system without using tools are disclosed. The welding system can include, for example, a robotic arm with a welding torch, an adaptor, and a wire feeder. The adaptor can include, for example, a quick-disconnect member located on the robotic arm. The wire feeder that can be removed from the adaptor after the quick-disconnect member has been actuated. The wire feeder can be installed and secured with tools by placing the wire feeder in the actuator and actuating the quick-disconnect member of the actuator.

Abstract: A wire conveying mechanism, preferably for a welding, cladding or additive manufacturing apparatus, with a slip clutch mechanism connectable to a motor. Such a wire conveying mechanism may include a wire feeder for feeding an electrode wire in a welding system having a drive roller assembly comprising a plurality of drive rollers to grip the electrode wire and to pull the electrode wire from an electrode wire source toward a conduit and a torque-managing device operatively coupled between a motor and the drive roller assembly, wherein the torque-managing device receives the rotational force from the first motor and regulates the first torque to output a second torque to the drive roller assembly.

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 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 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 conveying mechanism, preferably for a welding, cladding or additive manufacturing apparatus, with a slip clutch mechanism connectable to a motor. Such a wire conveying mechanism may include a wire feeder for feeding an electrode wire in a welding system having a drive roller assembly comprising a plurality of drive rollers to grip the electrode wire and to pull the electrode wire from an electrode wire source toward a conduit and a torque-managing device operatively coupled between a motor and the drive roller assembly, wherein the torque-managing device receives the rotational force from the first motor and regulates the first torque to output a second torque to the drive roller assembly.

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 weld cable connector system that includes a first terminal and a terminal protection system. The first terminal includes a first lock feature. The first terminal is configured to couple with a welding component and to conduct a welding power. The terminal protection system includes a cap, a base coupled to the first terminal, and a tether coupled to the base and to the cap. The cap includes a first mating lock feature. The cap is configured to removably couple with the first terminal in a first locking position to separate the first terminal from an external environment. The first mating lock feature is configured to interface with the first lock feature.

Abstract: A weld cable connector system that includes a first terminal and a terminal protection system. The first terminal includes a first lock feature. The first terminal is configured to couple with a welding component and to conduct a welding power. The terminal protection system includes a cap, a base coupled to the first terminal, and a tether coupled to the base and to the cap. The cap includes a first mating lock feature. The cap is configured to removably couple with the first terminal in a first locking position to separate the first terminal from an external environment. The first mating lock feature is configured to interface with the first lock feature.

Abstract: Embodiments of a pendant associated with a multi-process welding power supply that allows a user to switch processes and reverse an output polarity while located remotely from a power supply unit are provided. Certain embodiments include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Control circuitry that may include processing circuitry and memory is provided. The control system may disable redundant controls on the power supply unit user interface when the power supply unit is connected to the pendant via a supply cable. Additionally, the control system may set the process, set the polarity, enable or disable a wire feed, and enable or disable gas flow according to inputs received via a user interface on either the power supply unit or the pendant.

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 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: Embodiments of a pendant associated with a multi-process welding power supply that allows a user to switch processes and reverse an output polarity while located remotely from a power supply unit are provided. Certain embodiments include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Control circuitry that may include processing circuitry and memory is provided. The control system may disable redundant controls on the power supply unit user interface when the power supply unit is connected to the pendant via a supply cable. Additionally, the control system may set the process, set the polarity, enable or disable a wire feed, and enable or disable gas flow according to inputs received via a user interface on either the power supply unit or the pendant.

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: Embodiments of a pendant associated with a multi-process welding power supply that allows a user to switch processes and reverse an output polarity while located remotely from a power supply unit are provided. Certain embodiments include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Control circuitry that may include processing circuitry and memory is provided. The control system may disable redundant controls on the power supply unit user interface when the power supply unit is connected to the pendant via a supply cable. Additionally, the control system may set the process, set the polarity, enable or disable a wire feed, and enable or disable gas flow according to inputs received via a user interface on either the power supply unit or the pendant.