Abstract: A TIG (Tungsten Inert Gas) welding torch (10) comprises a torch body (22), a collet (38a,b,c) for retaining a tungsten rod, and a back cap (42), in which the collet 838a,b,c) passes through an aperture in the torch body (22) from the front of the torch body (22) to the rear of the torch body (22), and is joined directly to the back cap (42) by a screw thread (40a,b,c), the collet (38a,b,c) being drawn backwards against a front section of the torch body (22), to close the collet (38a,b,c) and retain the tungsten rod when the screw thread (40a,b,c) is tightened.

Abstract: A push-pull welding torch is disclosed. The welding torch includes a torch body and a unitary block disposed in the torch body. The unitary block includes an inlet channel, an outlet channel, and a gas channel fluidly connected to the inlet channel and the outlet channel. The inlet and outlet channels may receive a weld filler material. A quick release tensioner assembly is disclosed for a welding torch that may include a swing arm configured to mount to a drive block assembly via a pivot, a lever disposed between the swing arm and block assembly when the quick release tensioner assembly is mounted to the drive block assembly, a fastener disposed through the swing arm and lever, and a resilient member disposed between the fastener and swing arm. The fastener may be configured to engage the drive block when the quick release assembly is mounted to the drive block.

Abstract: Disclosed are systems and methods for feeding welding wire for welding-type applications. The wire-feeder system comprises a base platform, a spool hub, a drive roll assembly, and a wire guide assembly. The spool hub can be mounted to the base platform perpendicular to the base platform and configured to support a wire spool. The drive roll assembly can be mounted to the base platform, and having one or more sets of drive rollers configured to feed wire from the wire spool toward a welding torch. The wire guide assembly can be mounted to the base platform separately from both the wire spool and the drive roll assembly.

Abstract: Some examples of the present disclosure relate to welding torches having a thermal insulating plate (400). The thermal insulating plate is comprised of a thermally insulating material, and is positioned between a front housing (302) and a drive gearbox (324) of the welding torch. The front housing (302) is connected to a gooseneck that conducts electrical energy to a torch tip (i.e. front end) of the welding torch. The drive gearbox (324) includes a gear assembly configured to drive a drive roll that moves a wire electrode through the welding torch (e.g. toward the torch tip of the torch). The thermal insulating plate (400) acts as a heat dam to decrease and/or reduce thermal energy transfer from the torch tip of the welding torch (e.g. via the front housing) towards the rear of the welding torch (e.g. through the drive gearbox), where the thermal energy may heat the welding torch handle and/or damage some of the more expensive and/or sensitive components in the handle (e.g. a motor of the drive gearbox).

Abstract: Various methods of hardbanding an apparatus are described. In one aspect of the invention an improved method of re-applying a hardbanding alloy to worn tool joints of a previously hardbanded drill pipe results in preservation of the metallurgical properties of the drill pipe and preservation of the internal polymer coating that lines the drill pipe. A method for applying hardbanding includes arc welding a consumable metal welding wire to a tool joint having a surface temperature that ranges from about 50° F. to about 170° F. and the arc welding power supply utilizes DC current. The method herein produces a hardbanded tool joint comprising a heat affected zone (HAZ) of a based metal having a Rockwell hardness of 40 Rc or less.

Abstract: A welding training system includes a welding training software having three or more modes. The three or more modes include a live-arc mode, a simulation mode, a virtual reality mode, an augmented reality mode, or some combination thereof. The live-arc mode is configured to enable training using a live welding arc, the simulation mode is configured to enable training using a welding simulation, the virtual reality mode is configured to enable training using a virtual reality simulation, and the augmented reality mode is configured to enable training using an augmented reality simulation.

Abstract: A gas-fired heat gun is ignited using an electrode tip located downstream of a flame holder such that the electrode tip is in the path of the flowing gas. The electrode is connected to a voltage source that causes a spark to jump from the electrode tip to another part of the heat gun, such as the flame holder or a casing of the heat gun, when a trigger is pulled, thereby igniting the flowing gas. The electrode is typically a thin wire extending through a portion of a diffuser defining a portion of the gas flow path upstream of the flame holder. The electrode may be continuous from the diffuser to a terminal end downstream of the flame holder.

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 robotic accessory mounting assembly used in connection with a robot to attach an accessory to the robot, the mounting assembly including a cable connected to an implement mounted on the robot; the cable having a cable length; the implement including a first component having a first length, wherein the implement with the first component has an implement length that corresponds to the cable length; and a second component adapted to replace the first component, the second component having a length less than the first component, wherein replacement of the first component with the second component reduces the implement length defining a clearance relative to the cable length to receive an accessory mount in-line with the implement.

Abstract: A hand-turnable welding cable connection includes a welding cable portion and a cooperable welding torch portion. The welding cable portion includes a receiver having an opening defined by an inner, generally cylindrical surface. A slit extends through the receiver. A fastener extends across the slit generally transverse to a longitudinal axis of the receiver and partially protrudes into the opening. The welding torch portion includes a tubular member having a generally cylindrical outer surface. A transverse, circumferentially extending groove is formed on the outer surface of the tubular member. The groove may extend generally 90 degrees around the outer surface. A flat portion is formed on the outer surface of the tubular member. The flat surface extends longitudinally from an end of the groove toward an end of the tubular member. The welding torch portion is insertable in the welding cable portion, and the fastener engages the groove.

Abstract: A system and method for an integrated structural welding system is designed to improve work flow efficiency. Accordingly, a multi-cable umbilical cord system is provided that combines and couples a number of power, control, and gas deliver cables.

Abstract: In a welding wire storage device for a welding system including a housing with a wire core surrounding the welding wire being arcuately arranged to lie freely in a free space of the housing, one end of the wire core is fixed in an end region of the housing and a measuring means is provided to detect the deflection of the wire core. In order to provide a very simple and compact structure for such a welding wire storage device, the wire core is displaceably mounted in a guide element on the opposite end region, and two coupling mechanisms, for connection with a wire guide hose for the wire core are arranged on the housing.

Abstract: The invention relates to a welding wire conveyor device (1) and to a method for locking a pivotable roll receiver off the welding wire conveyor device (1) which comprises a drive roll receiver (11) and a pivotable pressure roll receiver (10). Said pressure roll receiver (10) can be coupled to a pivotable actuation means (20). Said pressure roll receiver (10) is locked in the pivoted position by means of a locking device (200) when the pivotable actuation means (20) is actuated.

Abstract: A cable management system for a welding-type system includes a support column extending in a first direction from a first end supported by a welding-type device to a second end arranged above the welding-type device. The cable management system also includes a cable support arranged on the second end of the support column that extends in a second direction substantially transverse to the first direction. Accordingly, a portion of the cable support extends away from the welding-type device to allow a cable supported thereon to extend below the cable support and proximate to the welding-type device.

Abstract: A welding system moves in a direction of travel, the welding system includes at least one torch directed toward a first location. The at least one torch each contains an electrode used to facilitate a weld, wherein a primary zone surrounds the electrodes in the first location. A secondary zone is located behind the primary zone with respect to the direction of travel, wherein a second gas line delivers shielding gas toward the secondary zone.

Abstract: A welding wire guiding liner has a plurality of guiding bodies connected to each other, each of the guiding bodies containing a plurality of rolling elements defining a guiding channel for the welding wire. Each guiding body has a ring which is coaxial with the guiding channel and is freely rotatable in a peripheral direction on the body. The ring is connected to the adjacent guiding body by means of a swivel joint which allows the adjacent guiding body to swivel around a swivel axis with respect to the guiding body provided with the ring.

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: An arc welding robot having a welding wire conduit which has a bend radius above a certain level and arranged so that disadvantageous stress is not applied to the conduit by the motion of the robot arm. A conduit for a welding wire is inserted through a hole of a robot pedestal from the rear side of the robot, is supported by a second support member arranged on the pedestal, extends near the front side of a rotating body of the robot, and is supported by a first support member on the upper part of the rotating body while having a required minimum bend radius. The conduit after passing through the first support member is introduced to the rear side of the upper arm and is connected to a connector at the rear side of a wire feeder while having the required minimum radius, whereby the conduit presents a generally S-shape.

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: 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: An electric arc welding machine includes a manual welding tool, an electric power unit, and a cable electrically connecting the welding tool and the electric power unit. The electric power unit includes an electric power converter, an electronic central control unit, and a control panel that allows the user to manually set a desired operating mode and operating specifications based upon equipment selected from a memory module. The electronic central control unit provides real-time control over electric power supplied to the welding tool in accordance with the manually set operating mode and selected equipment.

Abstract: A liner for guiding wire with low friction has a plurality of liner bodies carrying rolling elements. The liner body is connected with at least one adjacent liner body by means of a pivot connection. At least one of the liner bodies is connected to a first swivel joint body which in turn is connected to a second swivel joint body so as to form a swivel joint allowing rotation by more than 360° between the first and the second swivel joint bodies.

Abstract: Exemplary embodiments of the present technique relate to a welding storage structure. In one embodiment, a welding system includes a welding chassis and a storage structure that rotates outwardly from the welding chassis. In another embodiment, a welding system includes a welding storage unit having a storage base with a plurality of storage compartments, a cover removably disposed over the plurality of the storage compartments, and a rotatable chassis mount configured to couple the welding storage unit rotatably to a welding chassis.

Abstract: The present invention is related to a cable management system for a plasma cutter. The cable management system uses a flexible strap that is affixed to the housing of the plasma cutter and a loop is formed in the cable. The loop can be opened to align and position the cable with respect to the strap and the loop then can be easily closed to encircle the cable to secure the cable to the housing of the plasma cutter. By the present system, the portable plasma cutter can be transported by a user and the cables are securely fastened to the housing so as to prevent the cable from dragging or otherwise present a burden to the transportation of the plasma cutter.

Abstract: A method and apparatus for feeding wire from a source of wire to a weld includes one or more motors disposed adjacent the wire to drive the wire to the weld. A buffer is disposed between the source and an arc end of the torch. Another motor may be disposed near the wire source. A wire tension controller may be provided. The one or more motors advance and retract the wire, and wire is stored, or the path length altered, when the wire is retracted.

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: A welding implement includes a torch having a flexible torch head. The torch head is operable to conduct electricity to a welding electrode disposed within the torch head. The welding implement may include a gas supply tube and a coiled wire spring operable to flexibly couple the gas supply tube to the torch head. The welding implement may include a torch that directs a fluid to flow axially through a spring coupled the torch head. The welding implement may also include a torch including a torch head and a tripod support system to flexibly support the torch head. Each of the legs of the tripod support system may include a spring.

Abstract: A welding accessory system for a welder that includes a welder having a welder housing and at least one welding accessory support connected to the welder housing to support at least one welding accessory of a welder. The one or more welding accessory supports include a cable holder, an electrode holder, a cooling fluid holder, a cylinder gas holder, a cable connector box, and/or a tool holder.

Abstract: A robot main body is provided with a protection cover. The robot main body can be swung by a rotary pipe shaft holding a wire feed device and including a hollow portion and is structured such that a connecting cable and/or a gas hose are guided through the hollow portion of the rotary pipe shaft and are then guided through the forearm portion and base portion thereof. The protection cover covers the portions of the connecting cable and/or gas hose ranging from the connecting portion of the wire feed device and connecting cable and/or gas hose to the rotary pipe shaft.

Abstract: Accommodating a welding control cable for connecting a welding power supply and a robot main body and a wire feeder sensor cable connected to a wire feeder encoder in a robot main body driving power cable connecting the robot main body and the robot controller of an arc welding robot. This configuration saves the number of cables to be connected thus improving the installation workability in system deployment on site as well as reducing the overall cost.

Abstract: A lighter weight, more flexible coaxial welding cable assembly, and a system and method for constructing same. An embodiment of the coaxial welding cable assembly comprises a central electrical conductor length having a first cross-sectional area and a first insulating jacket surrounding the central electrical conductor length. The coaxial welding cable assembly also includes a plurality of peripheral electrical conductor lengths surrounding the insulated central electrical conductor length, where a total cross-sectional area of the plurality of peripheral electrical conductor lengths is approximately the same as the first cross-sectional area of the central electrical conductor length. The central electrical conductor length is electrically insulated from the plurality of peripheral electrical conductor lengths only by the first electrically insulating jacket.

Abstract: A highly durable cable hose assembly for connecting a welding machine to the conductor tube portion of a pressurized air cooled welding torch includes a cable hose, a rear connector portion for connecting to a welding machine and a front connector portion for connecting to the conductor tube. The cable hose portion includes a gas hose for passage of inert gas, a plurality of cooling air tubes for conducting cooling air, conductive stranding for conveying electrical current for arc welding and a flexible outer hose jacket for enclosing the gas hose, the plurality of cooling air tubes and the conductive stranding in a generally tightly bundled fashion.

Abstract: A welding accessory system for a welder that includes a welder having a welder housing and at least one welding accessory support connected to the welder housing to support at least one welding accessory of a welder. The one or more welding accessory supports include a cable holder, an electrode holder, a cooling fluid holder, a cylinder gas holder, a cable connector box, and/or a tool holder.

Abstract: An umbilical-member managing system for an industrial robot. The embodiment of the umbilical-member managing system provided in an arc welding robot serves to lay and manage, along a manipulator, a torch cable connected to a welding torch attached to the manipulator. This umbilical-member managing system includes a support unit provided on the manipulator movably toward and away from the welding torch to support the torch cable; and a biasing mechanism continually biasing the support unit on the manipulator in a direction away from the welding torch. In this arrangement, the support unit may be composed of a wire feeding device for feeding a welding wire in the torch cable toward the welding torch. A guide unit is provided on the manipulator, which can guide the wire feeding device in a direction toward and away from the welding torch.

Abstract: A power cable for use with welding apparatus for conveying power and cooling fluid from a welding machine to a welding torch. The cable includes an outer flexible conduit disposed about a flexible electrical conductor, a pair of end fittings operatively connected to the ends of the conduit and an electrical conductor for securing the power cable between the welding torch and welding machine in fluid and electrical communication therewith. The flexible conduit includes an inner tube portion formed of a flexible non-conductive rubber compound, a protective cover layer comprised of a plurality of threads braided or woven about the inner tube portion and a thin coating of a heat and wear resistant material such as polyurethane disposed over the braided or woven threads for bonding the protective cover layer to the inner tube portion, rendering the power cable heat and wear resistant without adversely affecting the flexibility thereof.

Abstract: A cable arrangement for a robot arm is provided, which includes a rotation arm and a line member such as a power cable. The rotation arm has a front end and a base end, the front end being provided with a swing shaft, the base end being provided with a rotational shaft rotatable about a longitudinal axis. The line member extends from the base end toward the front end of the arm. The rotational shaft includes a line offset member formed with at least one through-hole for passing the line member. The through-hole as a whole is offset from the axis of the rotational shaft.

Abstract: An umbilical-member managing structure for a welding torch in an arc welding robot. The umbilical members include a welding wire fed to the welding torch, a tubular liner surrounding the welding wire, a tube for supplying an assist gas to the welding torch, and an electrical conductor for feeding a welding current to the welding torch. The arc welding robot is provided with a wire feeding device mounted on the manipulator for feeding the welding wire to the welding torch. The umbilical-member managing structure includes a flexible conduit containing the umbilical members, which includes a first connecting section provided at one longitudinal end connected to the welding torch, and a second connecting section provided at another longitudinal end connected to the wire feeding device; and a connection mechanism for rotatably connecting the conduit to at least one of the welding torch and the wire feeding device.

Abstract: A first wrist element is rotatably provided on the front end of a forearm base of a robot. A second wrist element is rotatably provided on the first wrist element. A welding torch is rotatably supported via a transmission mechanism. A wire feeder is disposed at a position other than a forearm. A torch cable is fitted to a slider with an intermediate fitting section. A slider can be pulled backward by returning a wire connected to a tension generator using a pulley. In place of the fitting section, an intermediate guiding section can be provided.

Abstract: An arc welding cable that is resistant to bending and twisting and can give a long life is provided. For this purpose, an arc welding cable (65) for supplying a welding current, a welding wire and a sealed gas from a wire feeding device (61) to a welding torch (64), has a passage (4) for the welding wire (2) and sealed gas is located at a center of the arc welding cable and a plurality of conductors (5) are arranged apart from one another on a circumference around the passage (4). The space between the plurality of conductor (5) may be filled with a cushion material such as cotton or elastic synthetic resin.

Abstract: A first wrist element is provided at a distal end of a front arm of an arc welding robot rotatably about a first axial line, a second wrist element is provided on the first wrist element rotatably about a second axial line, and a welding torch is supported on the second wrist element about a third axial line. A slide mechanism which can reciprocate in a direction approximately parallel to the first axial line is provided at a proper position from an upper portion of the front arm to an upper portion of the first wrist element and a wire feeding apparatus is mounted on the slide mechanism. By sliding the position of the wire feeding apparatus in response to the attitude of the welding torch, an extending state of the torch cable can be maintained properly.

Abstract: A welding accessory system for a welder that includes a welder having a welder housing and at least one welding accessory support connected to the welder housing to support at least one welding accessory of a welder. The one or more welding accessory supports include a cable holder, an electrode holder, a cooling fluid holder, a cylinder gas holder, a cable connector box, and/or a tool holder.

Abstract: A welding accessory system for a welder that includes a welder having a welder housing and at least one welding accessory support connected to the welder housing to support at least one welding accessory of a welder. The one or more welding accessory supports include a cable holder, an electrode holder, a cooling fluid holder, a cylinder gas holder, a cable connector box, and/or a tool holder.

Abstract: A housing for a cable adapter assembly is featured. The housing may comprise a plurality of pieces that may be secured together, each piece forming a portion of the housing. The housing also may comprise a single piece having portions that are secured to each other around the welding cable adapter to form the housing. The single piece housing may be hinged. The housing may house a welding cable connector and the welding cable adapter. A method of converting a welding cable connector from one type of connector to another also is featured.

Abstract: A first wrist element is provided at a distal end of a front arm of an arc welding robot rotatably about a first axial line, a second wrist element is provided on the first wrist element rotatably about a second axial line, and a welding torch is supported on the second wrist element about a third axial line. A slide mechanism which can reciprocate in a direction approximately parallel to the first axial line is provided at a proper position from an upper portion of the front arm to an upper portion of the first wrist element and a wire feeding apparatus is mounted on the slide mechanism. By sliding the position of the wire feeding apparatus in response to the attitude of the welding torch, an extending state of the torch cable can be maintained properly.

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: 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 quick disconnect for use in a plasma arc torch is provided wherein a plurality of connections disposed therein are configured such that the connections break in a specific order when the quick disconnect is disengaged. Preferably, the quick disconnect comprises a plurality of signal pin connections, a pilot return connection, a fluid connection, and a main power connection. Accordingly, the signal pin connections break before the pilot return connection, the fluid connection, and the main power connection. Further, the pilot return connection breaks before the fluid connection and the main power connection, and the fluid connection breaks before the main power connection as the quick disconnect is disengaged. As a result, a safer quick disconnect in which both gas and electric power are conducted is provided by the present invention.

Abstract: This device significantly reduces major reasons for shielding gas waste primarily in metal inert gas welding. Excess shielding gas stored at the end of each weld in the shielding gas delivery hose connecting the gas source to the welding machine creates a shielding gas flow-surge at the next weld start. This gas flow-surge creates shielding gas waste and can cause poor weld start performance. Other methods employed over the years to reduce shielding gas waste have been either complex, leaked, were not sufficiently robust for the environment, provided only partial solutions or did not provide shielding gas savings for welds longer than about 3 seconds. This device includes a delivery hose connecting the shielding gas supply to the welding machine, which has a small internal volume and a gas surge-restricting orifice at the gas solenoid end of the hose.

Abstract: A welding accessory system for a welder that includes a welder having a welder housing and at least one welding accessory support connected to the welder housing to support at least one welding accessory of a welder. The one or more welding accessory supports include a cable holder, an electrode holder, a cooling fluid holder, a cylinder gas holder, a cable connector box, and/or a tool holder.

Abstract: The present invention provides a means of saving a significant amount of shielding gas, primarily in the metal inert gas (MIG) welding process. The invention significantly reduces a major reason for shielding gas waste, which is excess shielding gas storage in the hose connecting the shielding gas source to the welding machine. Other methods employed over the years to achieve the objective of reducing shielding gas waste have been complex, subject to leaks or were not sufficiently robust for the environment in which they are used therefore are not widely employed. The present invention consists of a hose connecting the shielding gas supply to the welding machine, which has a small internal volume. The outside diameter of the shielding gas delivery hose is sufficiently large and robust to provide satisfactory service in a welding fabricating environment.