Abstract: The invention described herein generally pertains to modular welding system which can switch between right-handed and left-handed wire feeders by use of the modular design and without having a duplicative dual feed system. This aspect is important with robotic welding as well as boom-mounted welding operations.

Abstract: In one embodiment, a system is provided with a welding wire feeder that a first wheel having a first rotational direction, and a second wheel having a rotational direction opposite from the first rotational direction. The first and wheels are disposed compressively about a wire feed region, and the first and wheels are drivingly coupled together to output substantially equal tangential in the wire feed region. In addition, the first wheel, or the second wheel, or first and second wheels comprise a drive wheel directly coupled to a gear separately coupling both the drive wheel and the gear to a shaft.

Abstract: A welding system including a fine tuning knob and a coarse adjustment knob for setting a weld wire feed speed are provided. The welding system may include a welder having the coarse adjustment knob and a spool gun having the fine tuning knob. A user may adjust the knob on the welder to set a coarse adjustment wire feed speed and may adjust the knob on the spool gun to fine tune the wire feed speed setting.

Abstract: A welding system and method includes a main torch including a main electrode configured to form a first arc with a base metal; a first bypass torch including a first bypass electrode configured to form a second arc with the main electrode; and a second bypass torch including a second bypass electrode configured to form a third arc with the main electrode.

Abstract: A welding apparatus having a system to facilitate its assembly. The apparatus is assembled by affixing a pair of molded end panels to a molded base and each of the end panels has a specially constructed receptacle area that is adapted to receive an end of the base. Each end of the base has a pair of snaps that extend outwardly and which engage with a correspondingly located pair of ramps formed in the receptacle area of each of the end panels. Thus the assembly is easily carried out by simply inserting the base ends into the receptacle areas where the snaps ride up the ramps and engage the vertical walls on the inner side of those ramps to securely affix the end panels to the base. Preferably the snaps are U-shaped in configuration with the distal end of the snaps being the closed ends of the U-shaped snaps.

Abstract: The invention relates to a contact tube (29) for a welding torch (10), having a longitudinal axis (31) along which a through-opening (30) for guiding a welding wire (13) from an inlet region (37) to an outlet region (35) and from an outlet opening (39) towards a workpiece (16) is provided, wherein at least one slot (34) is provided in the outlet region (35) for making contact with the welding wire (13). A contact tube (29) with improved contacting of the welding wire (13) is obtained by providing at least one further slot (36) in the inlet region (37) of the contact tube (29), wherein the slot (36) in the inlet region (37) is arranged in line with the slot (34) in the outlet region (35), and a web (38), which serves as a pivot point, is formed between the slot (34) in the outlet region (35) and the at least one slot (36) in the inlet region (37).

Abstract: A wire feeder includes a wire spool motor. The wire spool motor is configured to rotate a wire spool. The wire feeder also includes a motor control assembly configured to control rotation of the wire spool motor. The motor control assembly includes a control arm and a biasing member. The biasing member being configured to exert a force on the control arm to direct the control arm away from a forward control position. The wire feeder includes an enclosure housing the wire spool motor and the motor control assembly.

Abstract: A welding system is provided that includes a wearable wire feeder having a wire drive motor that is responsive to a control signal received directly from a power unit. Another welding system is provided that includes a wearable wire feeder that is configured to couple to a constant voltage power unit and does not include a voltage sensor. Another welding system is provided that includes a power unit, a wearable wire feeder separate from the power unit, a cable extending directly from the power unit to the wearable wire feeder and a welding torch coupled to and separate from the wire feeder. A method is provided that includes receiving a control signal from a power unit at a wearable wire feeder and driving a welding wire from the wearable wire feeder to a welding torch in response to the control signal, wherein the wearable wire feeder is separate from the torch.

Abstract: A retaining head for a MIG welding device includes a contact tip mounting end, an opposite retaining head mounting end, and a throughbore extending from one of the ends to the other end. A deflector is disposed along the throughbore and is adjustable for imparting a bend in welding wire passing through the throughbore. The deflector provides a straight wire contour for the welding wire that is fed out of the welding torch, while maintaining sufficient contact force between the welding wire and the contact tip. The deflector also reduces the effect of wire twist on the contact point between the welding wire and the contact tip.

Abstract: Provided herein are systems including a wire spool having a core with a core diameter and wire wound around the core and having a wire diameter. An outer diameter of the wire spool is defined by a sum of the core diameter and the wire diameter. The systems may also include a sensing system having a sensor component disposed on the wire spool and/or a wire spool hub. The sensing system is adapted to acquire data corresponding to a parameter indicative of the outer diameter of the wire spool.

Abstract: A welding gun, including a contact tip assembly, a diffuser cap, a tip holder, and a shielding gas diffuser, where the shielding gas diffuser includes a casing and an axial tube extending within the casing, and where the casing and the tip holder are connected via a connection system that includes threads with reduced peaks.

Abstract: A feeding lubricant for use on a welding electrode comprises about 10 to 40 wt. % of at least one soap-based lubricant, about 40 to 90 wt. % of at least one solid particulate lubricant selected from MoS2, WS2, ZnO, graphite and PTFE and up to 20 wt. % of at least one optional additional particulate lubricant ingredient.

Abstract: A connector for connecting a welding torch, where the connector body and the house are made of insulating material and designed as a unit in one piece connected by a rear wall. The connector includes an insert made of electrically conductive material carrying a threaded surface made of electrically conductive material and a contact surface. The insert can be fitted in a nest formed by a side surface of the connector body part and a surface of the house part opposite to the side surface. An opening on the sidewall of the house part provides access to the side surface of the insert for connecting the side surface to a current, and the insert is secured rotationally in the nest.

Abstract: The invention describes a method for welding a workpiece (16) with a consuming welding wire (13), the latter being moved substantially towards the workpiece (16) by a wire feeder (11) during a welding process, wherein a process is started and performed for removing slag (42) from the end of the welding wire (13).

Abstract: A modular portable welding wire feeder housed in a easily removable and interchangeable housing. The wire feeder includes a wire feeding module conveniently mounted inside of the housing. The housing is configured so that it may easily be removed from the wire feeing module, thereby allowing the housing to be easily replaced or exchanged as needed by the user.

Abstract: An electrode assembly and welding system and method. An electrode assembly preferably includes an electrode mounting block, a weld electrode disposed in said mounting block with a first end extending therefrom for contact with a work piece or a projection weld nut, an insulating bushing separating the weld electrode from direct contact with the mounting block, and a contacting electrode floatingly installed into a receiving cavity located in a second end of the weld electrode, the contacting electrode provided for contact by a gun arm electrode of a weld gun. A system and method of the present invention makes use of cooperating electrode assemblies to weld projection weld nuts to a fixtured work piece. Welding current is transferred from the electrodes of a weld gun to the projection weld nut(s) and work piece via the contacting electrodes and weld electrodes of associated electrode assemblies.

Abstract: The present invention includes a multi-use welding gun body configured for use in multiple locations along a welding gun assembly. In a particular embodiment, the multi-use welding gun body includes an enclosure forming an exterior surface of the body, the enclosure configured for both receiving a welding wire and a power source and directing the same toward a torch and having a first enclosure end with a wire-receiving aperture extending to an internal block-receiving cavity, the wire receiving aperture shaped to selectively receive a torch and an extension having an orifice containing both welding wire and shielding gas. The block-receiving cavity of the enclosure extends axially with a non-circular profile to a cable-receiving cavity within the housing, the cable-receiving cavity extending longitudinally to the second enclosure end. The second enclosure end includes an aperture forming an end of the cable-receiving cavity. A removable block is positioned within the block-receiving cavity.

Abstract: In a plate assembling step, a gap (5) is formed between a leading end portion (3A) of a groove (3) provided on an upright plate (2) and a lower plate (1). An arc is generated from a welding wire (7) toward a back surface (3C) side of the groove (3) through the gap (5), to form a satisfactory penetration bead (8) on the back surface (3C) side of the groove (3). Next, the welding wire (7), the lower plate (1), the groove (3) of the upright plate (2) and the penetration bead (8) are fused to form a first-layer welding bead (9), thereby firmly joining the lower plate (1) and the groove (3) of the upright plate (2). The first and second welding steps are performed continuously after performing the plate assembling step, to enhance workability at the time of welding the lower plate (1) and the upright plate (2).

Abstract: A spool gun having a quick connector connectable to an electrical power source and a gas source is disclosed. A connection line extends from the spool gun and is attached to a connector. The connector both fluidly connects the spool gun to a shielding gas source and electrically connects the spool gun to a power source constructed to generate a welding-type power. Such a spool gun is quickly and efficiently connectable to the gas and power systems required for performing welding processes.

Abstract: A contactor device used in a wire-feeder employed in a welding system is disclosed. The contactor uses oversized nuts, increased torque and surface features to increase the heat dissipation of the contactor. This solution is an economical way of increasing heat dissipation to extend the life of contactors that are subject to failure due to heating and increased internal resistance.

Abstract: A contact fitting for a welding apparatus includes a housing, and first contact device, a second contact device, and a third contact device arranged between the first and second contact devices. The third contact device is movable relative to the first and second contact devices. The first contact device has an elongated form, is fixedly arranged in the housing, and extends from a first end, which is arranged between first and second ends of the housing, to a second end. The second contact device has an elongated form, is suspended spring-loaded to the housing, and extends from a first end, which is arranged between the first and second ends of the housing, to a second end.

Abstract: A portable wire feeder for providing welding wire and welding current to a welding operation includes an input electrically connected to a power source. An output is selectively electrically connected to the input to receive welding current delivered to the input from the power source and to provide the welding current and welding wire to the welding operation through a guide hose. A contactor includes a first electrical terminal, a second electrical terminal and a conductive bridge member for selectively electrically connecting the input to the output. The first electrical terminal is electrically connected to the input. The second electrical terminal is electrically connected to the output.

Abstract: A laser-arc hybrid welding head performs laser light irradiation and arc discharge of a base material to weld the base material by combined use of laser welding and arc welding. The welding head includes an optical fiber for transmitting laser light used in laser welding and an arc electrode for generating an arc between the arc electrode and the base material. The optical fiber is disposed such that an optical axis thereof crosses an axis of the arc electrode at a predetermined angle.

Abstract: A weld stability system for an arc welding apparatus and method of operation is disclosed. The weld stability system may comprise a shielding gas supply and a control assembly. The shielding gas supply may include a first source of gas, a second source of gas, a mixing chamber, a first valve selectively connecting the first source of gas to the mixing chamber, a second valve selectively connecting the second source of gas to the mixing chamber, and a shielding gas supply line configured to direct gas from the mixing chamber to a weld gun. The control assembly may include a controller operatively engaging the first and second valves, and at least one sensor configured to monitor a parameter of an arc welding process and communicate with the controller.

Abstract: The invention relates to a device for buffering a welding wire, whereby a wire buffer, in particular a wire buffer magazine is arranged between a wire advance device and a further wire advance device which is preferably arranged in the vicinity of a welding torch, or in the welding torch and the welding wire is run between the two wire advance devices in a wire core. According to the invention, a simple and compact a buffer device as possible and an improvement in the dynamic behaviour of the wire supply can be achieved, whereby the wire core is attached or fixed at one end and the other end thereof is free to move and the wire core with the welding wire is arranged such as to be free to move within a wire guide tube with a substantially larger cross-section than the outer diameter of the wire core and the buffer volume of the wire buffer magazine is defined by the cross-section and the length of the substantially larger wire guide tube.

Abstract: Method for assembling a rack portion (1) of a self-raising oil rig, which rack portion (1) is constituted by at least one rectangular plate (3) which comprises teeth (51) at the longitudinal lateral faces (5) thereof, and at least one reinforcement (8) which is in the form of a half-shell and which is welded to a main face (6) of the at least one rectangular plate, along the longitudinal edges (11) of the at least one reinforcement, according to which an internal chamfer and an external chamfer which are separated by a projection of thickness T are produced at each of the longitudinal edges (11) of the at least one reinforcement (8), the at least one reinforcement (8) is provided at a main face (6) of the rectangular plate (3), at least one welding pass is carried out at the internal portion of each of the longitudinal edges (11) of the at least one reinforcement in order to produce an internal weld bead having a connection radius R greater than or equal to 4 mm, and the chamfers are filled at the external po

Abstract: A feeding lubricant for use on a welding electrode comprises about 10 to 40 wt. % of at least one soap-based lubricant, about 40 to 90 wt. % of at least one solid particulate lubricant selected from MoS2, WS2, ZnO, graphite and PTFE and up to 20 wt. % of at least one optional additional particulate lubricant ingredient.

Abstract: The invention provides a welding arrangement designed to respond to the need of an improved welding system that aids in supplying filler material to a weld location. Provided is a welding system including a welding gun and a welding wire feed directly coupled to the welding gun. The welding gun includes a filler material housing, a filler material positioning extension, and a manual advancement device configured to advance a filler material through the welding wire feed. Further provided is a method of operating a welding gun. The method includes passing a current between an electrode and a work piece at a weld location, and advancing a filler material toward the weld location via a channel of a positioning extension in response to engagement of a manual advancement device.

Abstract: Wire feed drive assemblies having welding wire mounted thereon and a motor that rotates a wire feed roller to drive the weld wire toward a welding torch are provided. The wire feed drive assemblies also include a temperature sensor coupled to the motor and adapted to measure a temperature of the motor. The wire feed drive assemblies further include a motor controller coupled to the temperature sensor and the motor and adapted to receive temperature feedback from the temperature sensor and to utilize the temperature feedback to regulate a speed of the motor.

Abstract: A modular welding wire feed drive for use in a welding system. The welding wire feed drive is designed to be detachably connected to the welding wire feed system of the welding system. The welding wire feed drive includes a drive housing designed to be detachably connectable to the welding wire feed system, a wire contact arrangement designed to controllably feed welding wire through the welding wire feed drive, and a drive motor that is connected to or interconnected to the wire contact arrangement to at least partially drive the wire contact arrangement.

Abstract: A drive roll for advancing a wire is provided. In certain embodiments, the drive roll includes a body having a wire feed portion, a mounting portion, and a central aperture through the body. In one embodiment, the feed portion includes an outer circumferential surface of the drive roll and a plurality of grooves for receiving and advancing various wires, while the mounting portion includes mounting features that are each uniquely associated with only one of the grooves. Various wire feed systems and welding systems are also provided.

Abstract: Embodiments of a welding system include a compact wire feeder adapted to feed welding wire having a diameter up to approximately 5/64 inches disposed on a wire spool having an outer diameter of approximately 8 inches. The compact wire feeder may include a housing, a spool mounting hub disposed in the housing and adapted to receive the wire spool, and a wire drive assembly having a motor adapted to apply an output torque to a shaft of a gearbox to drive the welding wire from the welding spool to a welding torch.

Abstract: A hybrid wire feeder including an energy storage device and a charging circuit are provided. The hybrid wire feeder may selectively alternate between utilization of power from the energy storage device and utilization of power from a welding power supply to power the weld and one or more weld sequencing events. Some embodiments provide for the energy storage device to be adapted to discharge during periods when the welding power supply is not outputting power and to recharge from the welding power when the welding power supply is outputting power.

Abstract: A welding gun assembly for directing a welding wire toward a workpiece, having a torch at a forward portion of the gun; a welding wire feeder at a rearward portion of the gun; and handles positioned adjacent the torch and wire feeder. Each handle has a first, cylindrical portion and a second, hexagonally shaped portion adjacent the first, cylindrical portion. The hexagonal portion has a cylindrical opening and a hexagonal opening adjacent the cylindrical opening. The handle further has an extension member having an access opening therein. A conduit is connected to each handle.

Abstract: A torch and a welder having a torch constructed to pull a consumable weld wire thereto are disclosed. The torch includes a wire feeder assembly having a first feed roll and a second feed roll. Operation of the feed rolls pulls a consumable weld wire to the torch. A lever selectively separates the first and the second feed rolls and is securable to allow a hands-free separation of the feed rolls.

Abstract: A spool gun having a quick connector connectable to an electrical power source and a gas source is disclosed. A connection line extends from the spool gun and is attached to a connector. The connector both fluidly connects the spool gun to a shielding gas source and electrically connects the spool gun to a power source constructed to generate a welding-type power. Such a spool gun is quickly and efficiently connectable to the gas and power systems required for performing welding processes.

Abstract: A wire feeder for laser welding is provided, comprising a body having a first end and a second end, and a longitudinal passageway extending from the second end to the first end, wherein the passageway is sized to permit passage of a wire therethrough. A wire feeding tube is connected to the first end of the body and in communication with the passageway, and a wire holder is connected to the second end of the body, wherein the wire holder contains a supply of wire. A feeding device is mounted on the body and in communication with the passageway, wherein the feeding device is adapted to urge the wire through the wire feeding tube. The wire feeder may be used for a variety of intricate welding operations, but is particularly suited for laser welding in the jewelry field.

Abstract: A welding system is provided that includes a wearable wire feeder having a wire drive motor that is responsive to a control signal received directly from a power unit. Another welding system is provided that includes a wearable wire feeder that is configured to couple to a constant voltage power unit and does not include a voltage sensor. Another welding system is provided that includes a power unit, a wearable wire feeder separate from the power unit, a cable extending directly from the power unit to the wearable wire feeder and a welding torch coupled to and separate from the wire feeder. A method is provided that includes receiving a control signal from a power unit at a wearable wire feeder and driving a welding wire from the wearable wire feeder to a welding torch in response to the control signal, wherein the wearable wire feeder is separate from the torch.

Abstract: An apparatus for feeding a wire. The apparatus includes at least one pair of rotatable rollers and at least one curved or curvable force-generating element. The at least one curved or curvable force-generating element is capable of applying a force via a proximal end of the at least one curved or curvable force-generating element to displace a first roller of the at least one pair of rotatable rollers towards a second roller of the at least one pair of the rotatable rollers to engage a wire there between. The apparatus further includes an adjustment mechanism operationally connected at a distal end of the at least one curved or curvable force-generating element to allow adjustment of the applied force.

Abstract: A modular welding wire feed drive for use in a welding system. The welding wire feed drive is designed to be detachably connected to the welding wire feed system of the welding system. The welding wire feed drive includes a drive housing designed to be detachably connectable to the welding wire feed system, a wire contact arrangement designed to controllably feed welding wire through the welding wire feed drive, and a drive motor that is connected to or interconnected to the wire contact arrangement to at least partially drive the wire contact arrangement.

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 dual power pin connector assembly for connecting both a MIG welding gun and a spoolgun to a welding machine. The dual power pin connector is comprised of a busbar portion that electrically and mechanically couples the positive output terminal of the welding machine power supply to a wire drive for the MIG welding gun. The connector is further comprised of an integral quick release assembly/clamping portion that electrically and mechanically connects the positive power supply terminal to a power supply cable for the spoolgun. The clamping portion receives and retains a power pin coupled to one end of the spoolgun power cable in a receptacle that is manually tightened and loosened.

Abstract: A modular portable welding wire feeder housed in a easily removable and interchangeable housing. The wire feeder includes a wire feeding module conveniently mounted inside of the housing. The housing is configured so that it may easily be removed from the wire feeing module, thereby allowing the housing to be easily replaced or exchanged as needed by the user.

Abstract: In a manufacturing method of an electric motor, at a time of in-sequence arc welding each of one end of a plurality of lined-up connector terminals to each of a plurality of lined-up detection signal output terminals by a welding rod provided in a torch of an arc welding machine, the method connects each of the other ends corresponding to the respective one end of a plurality of connector terminals to each of earth terminals of the arc welding machine in sequence.

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: An arc welding process using a consumable electrode, in which welding cycles follow one after another over the course of time, each comprising an arc period and a short-circuit period in which the liquid metal establishes a short-circuit between the end of the electrode and the workpiece or workpieces. Each cycle comprises the steps of: maintaining an arc current I2 at the same time as the consumable electrode is moved towards the workpiece; reducing the current so as to reach a minimum current I1 at the start of the short-circuit; reducing the speed of the consumable wire electrode; increasing the current over the short-circuit period in order to reach a maximum value I4; and then reducing the current over the short-circuit period in order to reach a minimum value I1.

Abstract: A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

Abstract: In a consumable electrode type welding method, while feeding a welding wire 1, a welding torch 4 is moved by a robot manipulator 9 in a direction where the welding torch 4 is pulled apart from a base metal 7, so that an initial arc is generated while the welding wire 1 is separated from the base metal 7. This not only can eliminate the need for the reversing operation of the robot manipulator 9 and thus can reduce the waste time to thereby be able to reduce a tact time but also can stabilize an arc in the welding start portion and thus can reduce the “unexpected stop” effectively.

Abstract: An arc welding apparatus includes a single-electrode type welding torch, a single wire feeder supplied with a plurality of welding wires and having a plurality of wire drivers for driving the plurality of welding wires, and a welding controller for controlling operations of the welding torch and the wire feeder. The welding controller selectively operates any one of the plurality of wire drivers to feed only a single welding wire to the welding torch and performs the arc welding. An arc welding robot system includes the arc welding apparatus, a robot mechanical part for holding the welding torch of the arc welding apparatus, and a robot controller for controlling operation of the robot mechanical part.

Abstract: The present invention is directed to a system for supplying a portable source of a consumable weld wire to a weld. The system includes a container having a length of consumable wire disposed therein and a wire drive assembly connectable thereto. The container may be a pail or bucket, and has an open end. The wire drive assembly has a base constructed to connect about the open end of the container. The wire drive assembly delivers the consumable weld wire from the container to a torch configured for welding-type applications. A system for supplying consumable wire such as herein disclosed is easily transportable, reusable, and functionally useful with many known welding devices.