Abstract: A welding torch maintenance apparatus and a welding tip changer are described. The welding torch maintenance apparatus and the welding tip changing apparatus each comprise a first gripping means for fastening the welding torch/diffuser so that the nozzle/welding tip is aligned with the rotational axis, a second gripping means for holding the nozzle/welding tip, the second gripping means rotates about the rotational axis to remove the nozzle/welding tip, and moves along the rotational axis. A drive means is provided for rotating the second gripping means, and a lift system is provided for moving the second gripping along the rotational axis. The welding torch maintenance apparatus further includes a cleaning means which enters the nozzle at the distal end and cleans an interior of the nozzle.

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 nozzle assembly for a welding torch is disclosed. The nozzle assembly comprises a nozzle, a contact tip, and a gas diffuser assembly. The gas diffuser assembly comprises a gas diffuser, coupled to an insulator. The gas diffuser is also coupled to a gooseneck and the contact tip. The nozzle is coupled to the gas diffuser assembly, such that the contact tip is retained within the nozzle. The nozzle and gas diffuser assembly further include complementary engagement features to couple the nozzle to the gas diffuser assembly. The nozzle also includes a spatter deflector configured to deflect or block spatter from obstructing gas holes of the gas diffuser assembly.

Abstract: Apparatuses, systems, and/or methods for providing welding systems or portions of welding systems that provide a tip-retention device that is configured to direct gas radially towards a contact tip.

Abstract: A welding gun is incorporated into a unidirectional welding system, where the unidirectional welding system includes: the welding gun performing welding when a set pressing force is applied; a power portion configured to generate power to be applied to the welding gun; a power connecting portion having one end portion connected to the power portion through a power wire and an opposite end portion engaged with the welding gun; and a power switch provided at the power connecting portion to selectively apply the power generated from the power portion to the welding gun.

Abstract: Provided is a wire body processing structure for a robot having a wrist, a base end of which is connected to a forearm in a rotatable manner about a first axis and a distal end of which has a plurality of working tools attached thereto. The wire body processing structure includes a first flexible conduit disposed along the first axis from the forearm to the distal end of the wrist and also includes a second flexible conduit disposed longitudinally within the first conduit. A first wire body for one of the working tools is extended longitudinally through the second conduit. A second wire body for another one of the working tools is extended longitudinally through a space between the first conduit and the second conduit.

Abstract: The present invention provides a fluid-related function device capable of suppressing deformation of a connection member and a case part which may adversely be generated by expansion of fluid stored in a space in which spatters at the time of resistance-welding are trapped. A pressure switch includes a space in which spatters generated at the time of projection-welding are trapped. The space is provided between a joint and a cap member. A communication passage brings inside and outside of the space into communication with each other. The communication passages is formed such that it permits fluid to pass through the communication passages and restrains spatters from passing through the communication passages.

Abstract: A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip.

Abstract: A mock welding unicoupon for a virtual welding system includes a first exterior surface and a second exterior surface perpendicular to the first exterior surface. The first exterior surface and the second exterior surface together provide a plurality of grooves configured for simulation of a plurality of different types groove welds on the mock welding unicoupon. A curved exterior surface is configured for simulation of a pipe fillet weld on the mock welding unicoupon. A magnet source is configured to generate a magnetic field around the mock welding unicoupon for tracking movements of a mock welding tool with respect to the mock welding unicoupon.

Abstract: A simulator facilitating virtual welding activity. The simulator may include a logic processor based subsystem operable to generate an interactive welding environment in virtual reality space that emulates welding activity by simulating a virtual weld puddle having dynamic, real time molten metal fluidity and heat dissipation characteristics, responsive to performing a simulated welding activity in real time. The simulator may include a foot pedal device in operative communication with the logic processor based subsystem and configured to affect a characteristic of the virtual weld puddle in real time, responsive to user control of the foot pedal device. The simulator may be configured to track the movements of a mock welding tool and a mock filler wire and determine interaction between the virtual weld puddle, a corresponding virtual welding tool, and a corresponding filler wire in virtual reality space that would result in the welding tool becoming contaminated.

Abstract: A method of forming a solder joint includes the steps of providing a heat shield member formed as an arcuate preferably metallic shell attached to a spring-clamp by means of an obedient shaft; attaching the spring clamp to a structure adjacent the solder joint; moving the heat shield member by bending the obedient shaft so that the heat shield member is positioned in a location spaced-apart from the solder joint with the concave surface of the heat shield member facing the solder joint; and applying heat from a torch to the solder joint from the side opposite the heat shield so that the heat shield reflects the heat back onto the solder joint.

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 torch shield includes a receptacle having a geometric shape with a central opening. A plurality of chains are disposed on the receptacle, such that the chains hang below the receptacle. A collar is connected to the receptacle for securing the receptacle to a shaft.

Abstract: A simple and inexpensive gas nozzle for arc welding capable of reducing adhesion of sputter and enhancing welding quality and welding workability. A gas nozzle (5) so fixed removably to the torch head (2) of a welding torch (1) as to surround a contact chip (4) for feeding a welding wire (W) is formed of a material, e.g., a pasteboard a part of which is carbonized through adhesion of sputter (S) and comes off together with the sputter (S). When the sputter (S) adheres to the gas nozzle (5) during welding, the adhering part is carbonized because of the heat of the sputter (S) and comes off together with the sputter (S). Consequently, adhesion and deposition of the sputter (S) onto the gas nozzle (5) can be reduced infallibly.

Abstract: A system and method for reducing the accumulation of weld spatter on welded automotive body panels and the adherence of weld spatter thereto including a compressed air supply, a liquid supply, a pump, at least one control valve, at least one regulator, a controller, and a material handling mechanism. The method includes positioning a body panel with respect to one or more spray nozzle assemblies, applying a controlled spray of anti-spatter liquid to the body panel surfaces prior to spot welding of the panel into a panel assembly, and shutting off the system pressure when the process is complete. The method also includes controlling multiple spray nozzle assemblies using a single pump, and rinsing the panels' surfaces after welding.

Abstract: Apparatus and method for use with a welding system. The apparatus and method provides a fluid bath which allows a welding nozzle of the welding system to be dipped into, for example, a friction reducing agent.

Abstract: A torch for MIG welding includes a gas nozzle for supplying a fluid therethrough to a workpiece, a tip disposed coaxially in the gas nozzle for supplying an electrode wire from a center thereof to a workpiece, and a rotor rotatably supported on the tip. The rotor includes a plurality of blades connected to a bearing rotatably supported on the tip for receiving rotary power due to a flow of fluid through the gas nozzle, a ring joining ends of the blades, and a plurality of spatter removal plates extending axially along an inner surface of the gas nozzle.

Abstract: A method of working metal in which molten metal particles are ejected from, for example, a welding electrode or from a metal workpiece being cut or drilled. The ejected molten metal particles are caused to pass through a contact region in which they make contact with a cryogen, for example, liquid nitrogen or solid carbon dioxide. The contact renders the particles non-adherent to any adjacent surface to which the particles would otherwise adhere. Alternatively, the adjacent surface may be cooled by contact with a cryogen so as to render the particles non-adherent thereto.

Abstract: Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns.

Abstract: The invention relates to a rotational flash guard and method of use of a rotational flash guard. In general, the flash guard is attached to a support frame by an arm, a linkage mechanism pivotally interconnects the arm and the support frame, and an extensible power member connects the support frame to the linkage mechanism. Due to the unique configuration of the rotational flash guard it is adapted for movement about a work piece positioner to allow for use of a robotic tool while providing protection to the operator and other workers.

Abstract: The invention relates to a stream nozzle (13) for an inert gas welding torch (B). The inventive nozzle is provided with a coating (S) that adheres to at least a part of the surface of said nozzle in a material fit and consists of silver, especially galvanically mounted contact silver.

Abstract: A cleaning system process and apparatus for welding torches performs the cleaning by subjecting the welding torch, including the weld tip, nozzle and gas diffusers, to cooling. The cooling provides a temperature shock sufficient to loosen the weld spatter from the torch. In one embodiment the loosened spatter may then be carried away from the torch by either or both of positive or negative fluid pressure, for example an air blast or a vacuum line, respectively. The cooling may be done by subjecting the torch to a pressurized flow of coolant medium such as dry ice pellets or the like. The system may further cleanse the torch with an anti-spatter compound which can be applied by mixture with the coolant medium if desired. The cleaning system process is thorough, quick, subjects the torch to little stress, and improves performance of the nozzle including operation time between cleanings.

Abstract: The invention relates to a method and a device for cleaning welding torches, for example in automated welding lines, on welding robots and in made-to-order production, by means of a cold medium, preferably CO2 dry ice. According to the method, a compressed air stream, charged with CO2 dry ice directed constantly or at intervals by a jet nozzle onto one side of the surface to be cleaned and simultaneously describes a rotational movement.

Abstract: An arc welding system using a wire to produce an arc. The arc welding system comprising a welding handle. A tip being disposed in the welding handle to direct wire through the welding handle. The tip having a passage through the tip to receive the wire. The tip having an end portion adapted to be in facing relationship with a target material during welding. The passage having an outer surface layer of electroless nickel. The end portion having an outer surface layer of electrolytic nickel.

Abstract: An electromagnetic weld spatter removal device wherein a single control and power source may be utilized to fire multiple electromagnetic coils, thereby producing a cost savings. A first embodiment of the invention includes a contactor switch mechanism, a control mechanism, at least two contactors, and at least two electromagnetic coils for removing weld spatter. There is also disclosed a method for removing weld spatter using multiple electromagnetic coils for multiple welding stations. In a second embodiment there is disclosed a single enclosure housing the power supply, control logic board, at least two SCRs connected to at least two coils for the removal of weld spatter.

Abstract: The invention relates to a stream nozzle (13) for an inert gas welding torch (B). The inventive nozzle is provided with a coating (S) that adheres to at least a part of the surface of said nozzle in a material fit and consists of silver, especially galvanically mounted contact silver.

Abstract: Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a welding nozzle [28 or 28a] and a portion of its related diffuser into a bath [12 or 12a] of fluid each time the automated welding system moves through a welding cycle. A product is also disclosed to best accomplish that step or element. Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the nozzle or diffuser.

Abstract: An electromagnetic weld spatter removal device wherein a single control and power source may be utilized to fire multiple electromagnetic coils, thereby producing a cost savings. A first embodiment of the invention includes a contactor switch mechanism, a control mechanism, at least two contactors, and at least two electromagnetic coils for removing weld spatter.

Abstract: Various methods, systems and products are disclosed for providing an improved welding system which substantially improves the continuous operation of an automated welding system by increasing the amount of time between maintenance shutdowns. One of the disclosed method steps or system elements provides for dipping a welding nozzle [28 or 28a] and a portion of its related diffuser into a bath [12 or 12a] of fluid each time the automated welding system moves through a welding cycle. A product is also disclosed to best accomplish that step or element. Another method step or system element may include the removal of spatter accumulation via an electromagnetic field that magnetically pulls the spatter without direct contact with the nozzle or diffuser.

Abstract: An electromagnetic weld spatter removal device wherein a single control and power source may be utilized to fire multiple electromagnetic coils, thereby producing a cost savings. A first embodiment of the invention includes a contactor switch mechanism, a control mechanism, at least two contactors, and at least two electromagnetic coils for removing weld spatter. There is also disclosed a method for removing weld spatter using multiple electromagnetic coils for multiple welding stations. In a second embodiment there is disclosed a single enclosure housing the power supply, control logic board, at least two SCRs connected to at least two coils for the removal of weld spatter.

Abstract: A welding torch flash shield is used with a welding torch to protect the eyes of personnel working near the welding torch. The torch flash shield is comprised of a flexible elongated sleeve having a first open end provided distal from a second open end. The first open end is configured to seat about a periphery of the nozzle end such that the sleeve extends from the nozzle end shrouding a welding wire of the welding torch. A retainer is configured to couple the flexible elongated sleeve to the periphery of the nozzle end. In addition, the second end flexes or flares to permit contact between the welding wire and a workpiece.