Abstract: A conductor tube for use in a welding gun, and preferably a MIG welding gun, is provided that includes a plurality of flex joints. The flex joints include a body defining a proximal end portion and a distal end portion, a cap secured to the proximal end portion of the body, and an extension mounted within the distal end portion of the body, the extension being repositionable within the body. The body, the extension, and the cap are adapted for attachment to each other and to adjacent components of the welding gun. Additionally, a conductor tube for use in a welding gun includes a plurality of thermally and electrically conductive elements secured to each other and extending along a length of the conductor tube, wherein the elements are independently repositionable relative to each other.

Abstract: A welding gun adapted to secure a contact tip within the welding gun without threading the contact tip and without the use of tools. The contact tip may be adapted to abut a surface of a first member disposed within the welding gun. The surface may be a surface of a gas diffuser. The surface may be adapted to abut the contact tip. The contact tip also may be adapted for abutment with a second member to urge the contact tip toward the first member. The second member may be a portion of a nozzle adapted to abut the contact tip to urge the contact tip toward the surface of the first member. A method of assembling a welding gun also is provided. The method may include disposing a contact tip between a first and a second member and capturing the contact tip between the first and second members.

Abstract: A securement member for securing a contact tip to a welding torch assembly is provided. A channel extends axially therethrough and has an internal shoulder that extends into this channel. This internal shoulder abuts against a shoulder on the contact tip, capturing the contact tip between the shoulder and a seating surface on the diffuser and securing the contact tip in the torch assembly. The contact tip is securely seated without threading engagement, facilitating quick release and installation. The exemplary securement member couples to the diffuser such that the egress of fluid from the diffuser is blocked when used for gasless welding. This blocking allows a user to leave the diffuser secured to the welding torch when a gasless electrode is in use.

Abstract: Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.

Abstract: An apparatus and method for feeding welding wire, where the apparatus contains a wire feeding device which pays out a wire and a power source which provides a current and voltage to the wire while it is being paid out. The apparatus further includes a detection circuit which detects a short circuit in the wire when the wire makes contact with a work piece or the like, and upon detection of the short circuit the wire feeding device stops feeding the wire so that a desired stick out distance is achieved.

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 torch comprising: a main cylindrical conductive assembly with a front diffuser section having a plurality of circumferentially spaced shielding gas diffuser orifices for directing shielding gas radially outwardly from the assembly, a forwardly facing threaded bore extending through a cylindrical support nose and an elongated wire passageway coaxial with the threaded bore and opening at the rear end of the assembly.

Abstract: A welding gun precludes moisture from penetrating inside of a motor housing due by preventing development of negative pressure inside the motor housing. The welding gun includes a feed screw mechanism that is coupled to a servo motor and has a hollow rod that reciprocally moves in a predetermined direction by way of torque applied by the servo motor, and a moveable electrode tip that is connected to a leading end portion of the hollow rod and opens and closes relative to a fixed electrode tip according to the reciprocal movement of the hollow rod. The servo motor has a motor housing in which a motor housing hollow part accommodating a portion of the hollow rod to be reciprocally moveable is formed. A vent that ventilates the motor housing hollow part with ambient air is formed in the motor housing.

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: A self-cleaning GMAW nozzle characterized by the inner surface thereof having a laminate group, preferably composed of sequentially alternating layers of metal and bonding material. Over a period of time of welding, welding spatter begins to accumulate upon an outermost metal layer of the laminate group. As the heat of welding proceeds over this same time, the adhesion of the adjoining bonding layer releases, whereby the outermost metal layer detaches, exposing a clean, new outermost metal layer. The process sequentially repeats until all metal layers have detached.

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 neck for a welding torch includes a rigid, non-tubular, elongated member having opposite first and second ends. The first end is connectable to a rear portion of the welding torch. The second end is connectable to a welding tip portion of the welding torch. The member locates and holds the welding tip portion in a precisely given location, and does not communicate welding power, welding wire, shielding gas, or cooling water between the first and second ends.

Abstract: A contact tip includes a first threaded section and a first non-threaded section. The length of the first non-threaded section is at least a fifth of the length of the first threaded section along a longitudinal axis. The contact tip further includes a first contact surface. A diffuser includes a second non-threaded section and a second threaded section configured to mate with the first threaded section of the contact tip. The diffuser further includes a second contact surface. The first non-threaded section is configured to elongate along the longitudinal axis as the first threaded section is screwed into the second threaded section past a point where the first contact surface and the second contact surface have established contact.

Abstract: A welding torch 30 has a first tip body 32, a pressurization shaft 43, and a second tip body 50 detachably connected to a distal end of the first tip body 32. A power supply tip 54 is accommodated in an accommodation hole 51 of the second tip body 50. The power supply tip 54 is removable from the accommodation hole 51 of the second tip body 50 after the second tip body 50 is removed from the first tip body 32. The power supply tip 54 is held in contact with the pressurization shaft 43 and urged by a compression spring 44 when the second tip body 50 is connected to the first tip body 32. A tip holder 60 is arranged at a distal end of the second tip body 50 in such a manner as to cover a distal end of the power supply tip 54.

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: 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: An improved plasma torch and method of starting the torch are provided. The torch may comprise a main torch body with an electrode assembly coupled to a piston therein. The piston and electrode assembly are moveable between a starting position whereby the electrode assembly contacts a nozzle, and an operating position whereby the electrode assembly does not contact the nozzle. The piston is moveable by directing fluid, which may comprise coolant, through the plasma torch either in a first direction which biases the piston to the starting position, or in an opposite second direction which biases the piston so as to retract the electrode assembly to the operating position. A reversing valve or reversible pump may be used to control the direction of the flow of the fluid. Thereby, the coolant supply may be used to both cool the torch and control the starting and operation of the torch.

Abstract: A welding wire conduit includes an outer tube, a wire spring disposed within the outer tube, and a plurality of cylindrical segments disposed within the wire spring. Each cylindrical segment includes a generally convex first axial end and a generally concave second axial end, and the first axial ends of the cylindrical segments are configured to mate with the second axial ends of the cylindrical segments.

Abstract: The high efficiency welding device has two pairs of clamps mounted in two pairs of sliders movable in a reciprocating movement relative to one another. One pair of sliders is mounted at 0 and 180 degree positions around the circumferential surface of a support block and the other pair of sliders is mounted at 90 and 270 degree positions. Each pair of clamps is in the close condition while moving forward in the reciprocating movement to clamp onto selected air gaps of the welding electrode to advance the electrode towards the work piece as well as delivering the welding current to the welding operation, and it is in the open condition releasing the grasp of the welding electrode while moving backward.

Abstract: A welding gun driving device is provided with an electric motor, a feed screw mechanism, and a pressure rod axially moved forward and backward via the feed screw mechanism by the electric motor. A rotor of the electric motor is formed into a hollow shape through which the pressure rod is insertable. The feed screw mechanism is provided with a screw shaft fixed to the rotor concentrically with the rotor, and a nut portion screwed to the screw shaft. The pressure rod is provided with the nut portion and a hollow rod portion extending toward the axial front from the nut portion. The rotor is provided, at its inner peripheral face, with a guide portion through which the pressure rod is inserted and supported so as to be relatively rotatable and axially slidable.

Abstract: A wire feeding unit for feeding a welding wire in a torch cable of a welding robot, the torch cable passing through the inside of an upper arm in its direction, includes a body member, which is mounted on an inner periphery of the upper arm in a state of being freely pivotable around the axis of the upper arm, and to which the torch cable is installed, and a feed roller mounted to the body member in a state of being freely rotatable around an axis orthogonal to the axis of the arm. Here, the welding wire exposed out of the torch cable is in contact with the circumferential surface of the feed roller and is fed by the rotation of the feed roller in a direction of the axis of the upper arm. According to the configuration like this, when an arm is pivoted, the torch cable passing through the arm is able to be prevented from being twisted.

Abstract: The present disclosure provides a welding system having a welder, a welding gun, and a welding gun adapter, the welding gun being a spool gun with an attached motor. The welding gun adapter receives welding power from the welder, and converts it to output power suitable for driving the motor of the welding gun. The welding gun adapter also uses received welding power from the welder for control power. The present techniques allow for the use of welding guns requiring motor power to be used with any ordinary welder.

Abstract: A cutting torch splatter and glare guard includes a collar that is structured for releasable engagement with a cutting torch. The collar has first and second collar portions that are biased towards a first position for engagement with the cutting torch and movable against the bias towards a second position for disengagement with the cutting torch. A guard plate coupled to the collar and structured to block splatter and cutting debris emanating from a cutting surface. A plurality of shield plates is pivotably attached to the guard plate so as to pivot info and out of an orientation extending generally perpendicular downwardly relative to the guard plate.

Abstract: A method and apparatus for reducing spatter is disclosed. A welding gun, which can be an integrated part of a welding system, includes a device, such as a solenoid or motor and roller, to slow, stop or reverse the wire. The device is activated in response to feedback indicative of a short, a short that is about to form, or the imminent clearing of a short. The detection of the short, forming of a short, or clearing of a short is in response to feedback based on current and/or voltage. Output current can also be reduced.

Abstract: A gas metal arc welding system that includes first and second welding torch assemblies arranged to operate in tandem. The first welding torch assembly further includes a rotable torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes an angled passage formed therethrough; a consumable wire electrode passing through the rotating torch body and exiting the contact tip through the offset exit hole; and a source of shielding gas. The second welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

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: A welding gun is provided that can achieve both a size reduction and increase in pressure using a servo motor. The welding gun (1,2) includes an arm holder (30) having guide pins (31a, 31b and 32a, 32b) that are moveable along guide tracks (12a, 12b) formed in a gun bracket (10), and a mobile gun arm (40) is mounted to this arm holder. Roller followers (33a, 33b and 34a, 34b) engaging with the guide tracks around the guide pins are provided, and the mobile gun arm is made to open or close via the arm holder using a servo motor (72).

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: An industrial robot has a base for installation, a first arm, a second arm, a third arm, a wire feeder, a welding torch, and a torch cable. The first arm rotates with respect to the base. The second arm pivots with respect to the first arm. The third arm pivots with respect to the second arm. The torch cable is coupled to the wire feeder and feeds a welding wire to a welding torch. The wire feeder is provided to the second arm and is rotatable around a rotation axis.

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 welding gun is provided that can endure high loads due to increasing the lead of the ball screw, while also being able to achieve a reduction in the size of a motor driving the ball screw. A welding gun equipped with a servo motor (10) as a drive source, includes: a hollow rod (43) that causes a moveable electrode tip (62) to advance and retract, a ball nut (42) that is coupled to the hollow rod (43), and a ball screw (41) that threadedly engages with the ball nut (42), in which a planetary gear reduction mechanism (70) is attached to the output shaft of the servo motor (10), and the ball screw (41) is attached to the output shaft of the reduction mechanism.

Abstract: A method for estimating a plurality of geometrical parameters defining the size of a weld gun that has particular application for automatically selecting a weld gun for a welding operation. The method includes iteratively estimating a plurality of geometric parameters based on part section curves corresponding to a direction of approach of the weld gun to weld point of the plurality of weld points. Thereafter, a set of valid weld gun sizes are calculated based on the estimated plurality of geometric parameters. Similarly all the valid weld gun sizes are calculated corresponding to each of the weld gun approach direction. Further, each set of the valid gun sizes are estimated for each of the weld point for the welding operation. Finally, a weld gun for performing the welding operation is selected based on the set of weld gun sizes corresponding to the welding operation.

Abstract: A wire feeder includes a wire feeder housing that may enclose one or more drive rollers rotatably connected with respect to the wire feeder housing for engaging welding wire. The one or more drive rollers may be adjustable and adapted to drive the welding wire to a welding gun connected to the wire feeder. A drive motor is incorporated for delivering power for rotating the one or more drive rollers. Friction reducing devices, such as bearings, may be utilized and positioned between one or more driver rollers and the housing, where the bearings are electrically non-conducting for preventing the discharge of electrical energy across the bearing surfaces.

Abstract: A contact tip for a welding torch includes a body having a front discharge end, an opposite rear feed end, and a bore extending through the body. A cap is mounted on the body at the front end. The cap has an aperture generally aligned with the bore. The cap is composed of a material having an electrical conductivity between 1.74×107 and 4.35×107 Siemens per meter at 20° C. The body is composed of a material selected from the group consisting of copper and a copper alloy. The body has an electrical conductivity that is higher than the electrical conductivity of the cap. A portion of the bore at the front end of the body and at least a portion of the aperture in the cap define a contact area for a consumable electrode wire.

Abstract: A wear resistant coating is applied on an elbow or S-bend by weld beads applied along a pipe. A rectangular support rod is attached inside the pipe by connectors so that wheels of the carriage are guided on the corners to maintain a fixed orientation relative to the support rod. A three axis robot arm carries an electric welding head so as to be able to dynamically adjust the head both angularly and radially. A welding wire is pulled to the head by a feeding system on the carriage. The weld parameters including a predetermined wire stick out and angle of wire attack are controlled. A drive motor carried by a drive carriage propels the drive carriage longitudinally along the support rod with a series of intermediate carriages.

Abstract: A welding gun is provided that includes a handle having forward and rear end portions and having a first passageway formed therethrough. A cable support tube having forward and rear end portions and a second passageway formed therethrough is secured to the handle at the forward end portion. A welding cable having a forward end portion and a rear end portion connected to a rear connector assembly extends from the rear end portion through the first and second passageways of the handle and the cable support tube to the forward end portion disposed within the forward end portion of the cable support tube.

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: A welding system including a welding power supply coupled to a wire feeder via a spool gun connection is provided. The welding system is adapted to utilize the power and control capabilities originating from the spool gun connection for wire feeder operations during an initial period. The wire feeder is adapted to utilize the welding arc power and an internal controller to power and control wire feeder operations after the initial period.

Abstract: A conduit constructed from a coiled wire having an oval or elliptical cross-sectional shape.

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 self-cleaning GMAW nozzle characterized by the inner surface thereof having a laminate group, preferably composed of sequentially alternating layers of metal and bonding material. Over a period of time of welding, welding spatter begins to accumulate upon an outermost metal layer of the laminate group. As the heat of welding proceeds over this same time, the adhesion of the adjoining bonding layer releases, whereby the outermost metal layer detaches, exposing a clean, new outermost metal layer. The process sequentially repeats until all metal layers have detached.

Abstract: A torch and a welding system having a pair of gas paths are disclosed. The torch includes a wire feed assembly and is connectable to a welding-type power source and a source of shielding gas. A power signal suitable for welding applications and a shielding gas are communicated through the torch. The shielding gas is communicated through the torch by a pair of gas passages.

Abstract: An invention is provided which comprises a welding gun assembly having a handle portion which is rotatable with respect to a fume tube assembly and a hose assembly to which it is coupled. The gun assembly employs a locking collar to secure the fume tube assembly to the handle portion which allows the handle portion to be positioned in any positioned within 360 degrees of a normal position, without the need for reconfiguring any other portion of the gun assembly.

Abstract: An apparatus and method for feeding welding wire, where the apparatus contains a wire feeding device which pays out a wire and a power source which provides a current and voltage to the wire while it is being paid out. The apparatus further includes a detection circuit which detects a short circuit in the wire when the wire makes contact with a work piece or the like, and upon detection of the short circuit the wire feeding device stops feeding the wire so that a desired stick out distance is achieved.

Abstract: A consumable electrode gas shield arc welding torch (20) includes a torch body (21), a tip body (22) mounted to a front end of the torch body, a tip holder (23) mounted to a front end of the tip body, a spring (26) provided in the tip body (22) in contact with the front end of the torch body (21), a pressing shaft (27) provided in the tip body (22) in contact with a front end of the spring 26) and a power feed tip (28) pressed by the pressing shaft (27) and the tip holder (23). The tip (28) includes a side surface having a projection contacting with a base end (23a) of the holder (23), with a space (29) defined between an inner surface of the holder (23) and a front end (28a) of the tip (28) when the front end (28a) of the tip (28) is inserted into the holder (23).

Abstract: A method and apparatus for using a collet to align and/or axially secure a liner within the gooseneck of a welding torch and to extend the useful life of the torch components are provided. A method and apparatus for securing torch components including said collet and including tapered locking engagement connections are also provided. A position of the liner with respect to a retaining head or a diffuser can be established and maintained, in spite of bending, swiveling, and other general movement of the torch, while still allowing flow of a shield gas past the collet. The welding torch components, including a gas diffuser, can be secured to the torch or other torch components via tapered locking engagements. The invention is useful for both manual and robotic torch systems.