Abstract: A contact tip for a welding gun having a central passage for a welding wire moving in a given direction toward a workpiece and receiving a welding signal by contact of the wire with the tip. The passage has an innermost end, an outermost exit end and a length. An opening in the contact tip intersects the passage so a pressure block slidably mounted in the opening is biased toward the wire by a spring around the contact tip urging the block against the wire. This tip is dimensioned and constructed to perform pulse welding by a relatively ductile wire.

Abstract: A welding gun attachment which converts a straight grip handle of a mig gun to a pistol grip handle. The pistol grip handle trigger is mechanically linked to the straight grip handle trigger so that movement of the pistol grip trigger causes corresponding movement of the straight grip trigger.

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: Devices and methods are provided that control gas flow to a plasma arc torch local to a torch handle. Generally, a plasma arc torch is provided that comprises a gas control device operable with a torch lead and a torch head, and an activation member operable with the gas control device. Accordingly, the activation member activates the gas control device such that gas flow is supplied from the torch lead to the torch head, and the activation member deactivates the gas control device such that the gas flow is terminated. Further, the activation member may comprise a trigger system, a button, or a safety member, among others. Moreover, the gas control device may comprise a gas control valve or a switch that activates a gas control device disposed within a power supply, among others.

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 welding gun includes a control switch combined with a trigger. The control switch features a slide movable to at least first and second positions. In an operating mode, the control switch switches between two differing sets of welding parameters in the first and second positions. In another operating mode, the control switch operates a safety lock-out, allowing activation of the welding gun by the trigger in one position and preventing activation in the other position. For operator convenience, the control switch may be positioned to slide transversely relative to the wire passageway of the weld gun with which the trigger is generally aligned.

Abstract: The invention relates to a method for cleaning a contact tube (20) of a welding torch (10), via which contact tube a welding wire (13) is supplied with electrical energy, said welding wire being moved towards the welding torch (10) by a wire reel (14) or a welding drum via a wire feeder (11), as well as to a welding plant (1) and a contact tube (20) for the welding torch (10) of such a welding plant (1). In order to prolong the service life of a contact tube (20) of a welding torch (10), the invention provides that the welding wire (13) is at least once moved backwards in the direction of the wire reel (4) or wire drum until the end (27) of the welding wire (13) lies at least within the length (36) of the contact tube (20), and that the welding wire (13) will subsequently again be moved forwards, in particular moved backwards into its starting position.

Abstract: A welding gun includes a handle, an input line, a neck and an acoustic wave trigger. The handle is configured to be grasped by an operator and includes first and second ends. The input line connects to a first end of the handle and is configured to deliver wire and/or gas to the welding gun. The neck is operatively connected to the second end of the handle. The wire and/or gas passes into the neck and out through a nozzle. The acoustic wave trigger is secured to the handle and activates the welding gun when merely touched, as opposed to being squeezed or pressed, by the operator.

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 wire feed assembly and torch and welding systems are disclosed. The wire feed assembly includes a motor drivingly connected to at least one roll of a pair of rolls. A controller is connected to the motor and is constructed to control the operation thereof. A knob is rotatably connected to the controller and facilitates an operator's adjustment of the controller. A collar is disposed between knob and the controller and is fixedly connected to the controller and engaged by the knob to resist movement of the knob and thereby adjustment of the controller.

Abstract: An ergonomic handle attachment to be used with a welding torch handle, the attachment has an attachment portion which is selectively attached to a wall of the handle; a hand grip portion which is selectively attached to the attachment portion, and, a locking member extending from the hand grip portion which is slidably received within an opening of the attachment portion.

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 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 motorized wire feeding system includes a motor and a feed roll driven by the motor to direct the wire from a wire supply to the output for provision of the welding wire to the welding operation through the guide hose. Power for the motorized wire feeding system is drawn from the welding current passed from the input to the output. A grounding assembly nonattachably contacts a work piece of the welding operation to electrically ground the power drawn from the welding current directly to the work piece.

Abstract: A welding torch has a nozzle; a contact tip positioned within the nozzle; a tube extending from the nozzle; wherein the tube has a gooseneck portion having a radius, and the tube has a second portion adjacent the nozzle which has a longitudinal axis which is substantially collinear with a longitudinal axis of the nozzle. The gooseneck tube has a single radius extending from a distal portion to a proximal portion of the tube.

Abstract: An ergonomic handle attachment to be used with a welding torch handle, the attachment has an attachment portion having a first wall that is selectively attached to a wall of the handle and a second wall which extends from the first wall and is selectively received by an opening in the wall of the handle. A locking member is slidably received within the opening of the second wall and the wall of the handle when the opening of the second wall and the opening of handle are substantially aligned with each other.

Abstract: A welding torch is provided that includes a motorized arrangement for advancing continuous electrode wires during welding. The torch has a pair of rollers that contact the electrode wire to force it through the torch during welding. A force adjustment selector is provided in the torch handle that allows the operator to alter the force or pressure applied to the electrode wire. Markings on the handle, or stops provided between the selector and the handle allow for easy adjustment and verification of the proper pressure or force applied for specific types of electrode wires.

Abstract: An improved liner for protecting an electrode wire within a body of a welding torch. The liner includes a liner retainer, which is removably coupled to a liner insert. The liner retainer is secured to a distal end of the welding torch and the liner insert is inserted and coupled to the liner retainer through a proximal end of the welding torch.

Abstract: An attachment device for use in connecting a conductor tube to a handle of a welding gun is provided that includes an adapter disposed proximate the handle of the welding gun, wherein the adapter defines a plurality of radially spaced receiving portions. A conductor tube is disposed adjacent the adapter, and the conductor tube defines at least one extension disposed near a proximal end portion of the conductor tube. The plurality of radially spaced receiving portions are adapted for engagement by the extension of the conductor tube such that the conductor tube can be repositioned relative to the handle of the welding gun.

Abstract: A welding system having a welding implement. The welding implement having a neck, a handle and a retaining nut for securing the neck to the handle. The neck being operable to convey electrode wire therethrough. The retaining nut being adapted for wrench-tightening to a threaded portion of the welding implement. An optional retaining nut operator. The optional retaining nut operator being adapted to secure to the retaining nut. The optional retaining nut operator being adapted for manual rotation to thread the retaining nut to the threaded portion of the welding implement. The optional retaining nut operator may be adapted to snap-fit onto the retaining nut. The optional retaining nut operator may include an electrically insulating material. The electrically insulating material may include a polymer.

Abstract: Several aspects of an in-line welding gun are disclosed. In one aspect, the welding gun has a variable profile insulating boot disposed over the torch barrel of the gun. The variable profile insulating boot may include a molded material having varying thickness to provide the desired insulating properties. In another aspect of the welding gun, a speed control mechanism for the motor driving the wire feed assembly is positioned in a recess in the housing such that it reduces the risk of being unintentionally adjusted during operation of the welding gun. In another aspect of the welding gun, the wire feed mechanism features a feeder roller and an idler roller that may be separated without opening the housing of the welding gun. To separate the rollers, the user may depress a portion on the exterior of the housing to press on a pivotable lever on which the idler roller is disposed.

Abstract: In accordance with one exemplary embodiment, there is provided a welding torch that includes features facilitating aligned assembly of various components of the welding torch with respect to one another. For example, the welding torch includes a nipple that carries a pin member extending from both an inner peripheral surface and an outer peripheral of a sleeve of the nipple. This pin engages with a slot on a coupling member and a slot on a neck assembly, thereby facilitating proper alignment of the neck assembly, coupling member, and nipple with respect to one another. Moreover, the engagement between the pin member and the slots block pivotal displacement of neck assembly, coupling member, and neck assembly with respect to one another. Advantageously, the use of a single pin member for both slots presents a more judicious construction, leading to reduced manufacturing costs, for instance.

Abstract: In accordance with one embodiment, there is provided a welding torch nipple for coupling a welding cable and neck assembly to one another. The exemplary nipple includes two hollow tubes: an inner tube disposed in an outer tube. The inner tube includes features that facilitate mating with a welding cable and the outer tube is configured to receive a neck assembly. A dielectric layer disposed between the inner and outer tubes electrically isolates the outer tube from the inner tube, thereby protecting a user from electrical shock, for instance. The dielectric layer includes a stem portion that extends radially into the outer tube, blocking axial separation of the outer tube and the dielectric layer.

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 welding gun having a swivel coupling joining the posterior end of the gun to the handle thereby allowing the handle and gooseneck to be rotated without having to rotate the posterior end of the gun and the wire cable feed line, the swivel coupling providing a conduit for welding gun wires and hoses and limiting the rotational range of the handle, thereby reducing stress to the wires and hoses.

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 comprise disposing a contact tip between a first and a second member and capturing the contact tip between the first and second members.

Abstract: A motor-driven welding gun has a servomotor for displacing a movable electrode tip toward and away from a fixed electrode tip. The servomotor has a motor housing with a copper pipe which is inserted therein when the motor housing is cast. The copper pipe provides a coolant passage in the motor housing for supplying a coolant therethrough. When the coolant passage is supplied with the coolant, the motor housing is forcibly cooled, reducing the amount of heat generated by the servomotor.

Abstract: A welding system having a welding gun with a self-contained trigger and trigger locking assembly. The self-contained trigger and trigger locking assembly has a trigger that is pivoted to operate the power source. The self-contained trigger and trigger locking assembly has a movable stem that pivots with the trigger and a stem receiving portion that is operable to receive the stem. The stem receiving portion acts to restrict pivotal movement of the stem so to maintain the trigger pivoted in position to continue operation of the power source.

Abstract: An in-line welding gun includes a mounting block, a wire feed mechanism and a torch barrel. A motor is positioned behind the mounting block along a longitudinal axis of the gun. The torch barrel curves away from the longitudinal axis. The motor and the torch barrel are surrounded by a substantially rigid shell comprising a tubular portion and a torch portion.

Abstract: A welding system having a welding implement with a self-contained trigger and trigger locking assembly. The self-contained trigger and trigger locking assembly has a trigger which, when operated, regulates the flow of current from a power source. The trigger lock of the assembly has a movable portion which includes a groove which can engage a complementary structure on the trigger to maintain the trigger in an operating position, thereby allowing continued flow of current from the power source.

Abstract: A welding system having a welding gun. The welding gun is adapted with a trigger. The welding gun may have a lever to lock the trigger in a desired pivoted position. The lever may pivot the trigger as the lever is pivoted. The welding gun may have a trigger extension to enable a user to pivot the trigger by depressing the trigger extension. The trigger extension may be plastically deformed. The trigger extension may be removable. The trigger extension may be rotatable.

Abstract: A plasma arc torch includes at least one consumable component in coaxial relationship with another component of the torch. At least two compressible components are disposed between longitudinally extending coaxial surfaces of the consumable component and the second component. A pressurized medium flow path is directed to a longitudinal location between the compressible components. Upon supply of a pressurized medium through the flow path, the compressible components are caused to deform radially outward thereby centering the consumable component relative to the other component.

Abstract: A magnetically-actuated switch adapted to control a welding device. The magnetically-actuated switch may comprise a set of electrical connectors that are brought into electrical communication with one another by magnetic force. The magnetically-actuated switch may be disposed within a welding implement coupled to the welding device. The welding implement may be operated by disposing a magnet proximate to the welding implement to actuate the magnetically-actuated switch. The magnet may be disposed within a magnet holder securable to a hand.

Abstract: A positionable welding torch for a welding system is featured. The torch comprises a torch head, a handle, and a flexible portion coupled to the torch head and the handle. The flexible portion is adapted to enable the torch head to be positioned relative to the handle. The flexible portion has a first end, a second end, and a rigid restraining member adapted to cooperate with the first and second ends to limit the relative displacement of the first and second ends. The restraining member may comprise a restraining portion adapted to abut one of the first and second end portions. The restraining member also may comprise a biasing portion adapted to bias the restraining portion into engagement with one of the first and second end portions. A method for assembling a welding torch having a restraining member also is featured.

Abstract: The present invention relates to a strain relief mechanism for a plasma arc torch. In particular, the invention relates to a strain relief system including a positive axial restraint component for restraining axial movement of a lead relative to a housing and a positive rotational restraint component for restraining rotational movement of the lead relative to the housing, wherein the positive axial restraint component and the positive rotational restraint component are independent components arranged in a spaced relationship relative to each other.

Abstract: A welding gun having a removable end portion. The end portion may be adapted to direct gas from the welding gun. The end portion may be conical-shaped. The end portion may be removed without tools. The end portion also may be adapted to be secured to and/or removed from the welding gun in a linear movement. A method of assembling a welding gun. The method may comprise urging a nozzle end member and a nozzle body into engagement to secure the nozzle end member to the nozzle body.

Abstract: A welding system having a welding gun with a handle. The handle has a first end and a second end. The handle may be operable to receive a welding cable from a first and a second direction, respectively. The handle may be operable to position a trigger in any one of four quadrants of the handle. The handle may increase in cross-sectional area in each direction from a gripping portion located between the first and second ends towards the first and second ends.

Abstract: A welding torch (2) for use in gas metal arc welding, which welding torch (2) comprises a neck portion (4), a diffuser (6) at a first end (8) of the neck portion (4), a contact tip (10) which extends from the diffuser (6), connector means (12) which is at a second end of the neck portion (4) and which is for connecting the neck portion (4) to a power cable assembly (16), and a trigger switch (114): the power cable assembly being such that it supplies electricity and gas to the welding torch (2) with the gas being for protecting welds from atmospheric contamination as the welds are made using the welding torch (2); the neck portion (4) being such that it comprises an electrical conductor (20) and a passageway (22) for the gas; the neck portion (4) being such that it comprises insulation (26) in the form of an overmoulding of a plastics material, the overmoulding being such that it also provides rigidity and impact strength to the neck portion (4); the trigger switch (114) being a snap fit in position in a sock

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: A welding gun having a removable end portion. The end portion may be adapted to direct gas from the welding gun. The end portion may be conical-shaped. The end portion may be removed without tools. The end portion also may be adapted to be secured to and/or removed from the welding gun in a linear movement. A method of assembling a welding gun. The method may comprise urging a nozzle end member and a nozzle body into engagement to secure the nozzle end member to the nozzle body.

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 comprise disposing a contact tip between a first and a second member and capturing the contact tip between the first and second members.

Abstract: A welding system having a welding implement with a self-contained trigger and trigger locking assembly. The self-contained trigger and trigger locking assembly has a trigger which, when operated, regulates the flow of current from a power source. The trigger lock of the assembly has a movable portion which includes a groove which can engage a complementary structure on the trigger to maintain the trigger in an operating position, thereby allowing continued flow of current from the power source.

Abstract: A welding system having a welding gun. The welding gun is adapted with a trigger. The welding gun may have a lever to lock the trigger in a desired pivoted position. The lever may pivot the trigger as the lever is pivoted. The welding gun may have a trigger extension to enable a user to pivot the trigger by depressing the trigger extension. The trigger extension may be plastically deformed. The trigger extension may be removable. The trigger extension may be rotatable.

Abstract: A welding system having a welding gun with a self-contained trigger and trigger locking assembly. The self-contained trigger and trigger locking assembly has a trigger that is pivoted to operate the power source. The self-contained trigger and trigger locking assembly has a movable stem that pivots with the trigger and a stem receiving portion that is operable to receive the stem. The stem receiving portion acts to restrict pivotal movement of the stem so to maintain the trigger pivoted in position to continue operation of the power source.

Abstract: An inner torch for the electric-arc spraying of cavities, in particular of cylinder contact surfaces. The inner torch as at least two torch tubes for heating electrodes. The electrodes are provided for melting purposes and are designed as wires which can be burned away in an electric arc. The inner torch also has a gas feed for a process gas which is provided for transporting and spraying the molten wire material in the direction of the cavity surface which is to be coated. The wires are guided towards one another, by way of the torch tubes, wherein at the outlet and in the region of the electric arc, the electric arc of the electrodes wires, which is arranged in the contact region of the wires, is arranged in the region of the flow of the discharged process has, referred as the main gas arranged transversely to the main transporting direction of the wires. Furthermore, in addition to being bent towards one another, the wires are also bent transversely to this direction.

Abstract: A welding gun includes a welding handle and at least one interchangeable assembly. A plurality of interchangeable assemblies are securable to the welding handle to enable the welding gun to be configured for operation in a plurality of welding applications. A first interchangeable assembly enables the welding gun to receive gas and wire. A second interchangeable assembly enables the welding gun to receive flux and wire. The welding gun is coupled to a power source. The welding gun may be coupled to a flux reservoir or a source of gas. The welding gun may be coupled to the system by a cable operable to convey wire, gas, and flux to the welding handle.

Abstract: A welding system having a welding gun. The welding gun having a neck, a handle and a retaining nut for securing the neck to the handle. The retaining nut consists essentially of a polymeric material. The polymeric material may be polyphenylene sulfide (PPS).

Abstract: The attachment provides an overhandle, which overlies the handle of the torch, thereby creating a tapering space. The welder places the first web area of the hand into the space, whereupon the connection between the hand and the torch is made more secure. The welder can manipulate the torch, without the need to exert a constant tight gripping force on the torch. The attachment includes side-cheeks which provide even more of a constraining connection between the hand and the torch. The attachment is adjustable as to position and angle with respect to the torch.

Abstract: A welding system having a welding gun with a handle. The handle has a first end and a second end. The handle may be operable to receive a welding cable from a first and a second direction, respectively. The handle may be operable to position a trigger in any one of four quadrants of the handle. The handle may increase in cross-sectional area in each direction from a gripping portion located between the first and second ends towards the first and second ends.

Abstract: A welding system having a welding gun. The welding gun having a neck, a handle and a retaining nut for securing the neck to the handle. The retaining nut consists essentially of a polymeric material. The polymeric material may be polyphenylene sulfide (PPS).