RU2804429C2 - Wire feeder - Google Patents

Abstract

FIELD: arc welding.

SUBSTANCE: device for feeding the wire into the welding device comprises an outer casing and an inner casing, which form an intermediate space between the outer and inner casings. The inner housing houses the components of the wire feed mechanism. A part of one of the components, in particular a part of the current-carrying bar, is placed in the intermediate space. Openings in the inner and outer housings of the device provide a closed loop airflow to circulate air through the intermediate space. The device is equipped with a power connector for incoming power cables.

EFFECT: cooling to the components of the wire feeder, as well as a reduction in the weight of the wire feeder, while having the structural rigidity required for the wire feeder.

10 cl, 15 dwg

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims benefit from U.S. Provisional Patent Application No. 62/754,853, filed November 2, 2018, the contents of which are incorporated herein by reference in their entirety.

FIELD OF TECHNOLOGY TO WHICH THE INVENTION RELATES

[0002] The present invention relates to a wire feeder, and more particularly to a portable wire feeder for feeding welding wire and supplying power to a welding torch.

BACKGROUND OF THE ART

[0003] Portable welding devices (eg, welding power source, wire feeder, etc.) are known and are often sold in a case. These portable welding devices are used in applications where it is impractical or inconvenient to send the workpiece to a shop for repair or fabrication. Examples of applications for such portable welding devices include petroleum and chemical production, shipboard installation and repair, and the like. The portability of these welding devices has made them widely used and popular. Among the various types of welding, portable welding machines are often used for metal arc welding in a gas environment. Gas arc welding has several advantages over other types of welding, including deposition rate, speed, superior weld quality, minimal distortion of the workpiece, and no waste to cinders. In conventional metal inert gas (MIG) welding, the MIG welding machine includes a torch and a welding wire electrode fed continuously from a feed spool or other source by a wire feed mechanism to the welding torch. The arc between the torch and the workpiece continuously melts the welding wire electrode, forming a weld pool.

[0004] One problem with prior art portable welding devices is that they are not robust enough to withstand the harsh handling and environmental conditions that portable welding devices encounter during transportation and use. When welding machines are robust enough, they become heavy, which reduces their portability. In addition, known portable welding devices cannot operate effectively in the harsh environments in which portable welding devices are used. Due to the nature of the environment in which such portable welding devices are used, they can become damaged and may require repairs at shorter intervals than desired. The nature of the environment in which such portable welding devices are used also creates problems with cooling the components within the portable welding device, since outside air creates problems when used to cool the internal components. The environment in which portable welders are used often contains various contaminants and contaminants that can damage the components (both internal and external) of the portable welder. In addition, cooling the internal components within the portable welder requires inlet and outlet openings in the body of the portable welder, which may allow water to enter the interior of the portable welder and thereby damage the internal components. Another problem with known portable welding devices is that they may not be light enough to grip, lift and carry. This may be due in part to the heavy nature of welding devices. In addition, prior art portable welding devices may not be designed to allow individual parts of the portable welding device to be easily repaired/replaced if they become damaged during or after use of the welding device.

[0005] Electrode wire feeders may be one embodiment of the portable welding devices described above. These electrode wire feeders contain wire feeders that include opposing feed rollers that apply pressure to the welding wire passing between them and are driven by engaging mechanisms to feed the electrode wire to and through the torch. In some cases, one pair of opposing feed rolls is used, while in other cases two pairs of feed rolls are used, spaced apart along the wire feed path. Wire feeders also receive welding power from the power source and transfer it to the welding torch. Thus, wire feeders also include various conductive bars running within the wire feeder. The wire feeders may also be configured to control the flow of shielding gas to the welding torch, as well as control various welding operating parameters to perform the welding operation. Given the complex nature of the wire feeder and its internal components, the role of the wire feeder in facilitating MIG welding operations, and the known problems with conventional portable welding devices described above, current portable wire feeders are not viable long-term solutions for portable welding operations.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a reliable and portable wire feeder for facilitating welding operations. This wire feeder contains many features that give it advantages over conventional wire feeders. The wire feeder body includes an inner body structure and an outer body structure that are connected to each other. This creates a double-walled enclosure with an intervening space located between the external enclosure structure and the internal enclosure structure. The external structure of the housing can be made of a more flexible and resilient material compared to the internal structure of the housing. In addition, the internal structure of the housing may be more rigid than the external structure of the housing. This design allows the external structure of the housing to withstand damage in the harsh environments in which wire feeders are used. The double-wall design also allows the case to be rigid without the use of heavy and bulky materials such as heavy metals. This reduces the weight of the wire feeder, making it more portable.

[0007] In addition to this, as explained previously, the double-wall structure creates an intermediate space between the outer body structure and the inner body structure. This interstitial space can be used to reduce the amount of heat that accumulates in the internal cavity of the wire feeder. The busbars that provide welding power and also power various wire feeder components may primarily pass through the interstitial space. This allows the heat generated by the busbars to be more easily dissipated through the external structure of the housing, while the internal structure of the housing serves to insulate the internal cavity from the heat generated by the busbars. In addition, the circulation fan or pump may be configured to circulate air from the internal cavity of the wire feeder along a closed circulation loop through the intermediate space. This closed circuit serves several purposes. Heat absorbed by the circulating air can be more easily dissipated through the outer structure of the housing as air is pumped through the interstitial space. In addition, the circulation of air through the intermediate space and ultimately over the busbars passing through the intermediate space serves to further cool the busbars by convection. In addition, due to the closed circulation loop, contaminated air from outside the wire feeder is never pumped into the wire feeder, where contaminated air can contaminate components located inside the wire feeder.

[0008] Wire feeder doors may also be equipped with storage compartments located on the inside of the doors. These storage compartments may be configured to accommodate consumable components of the wire feeder and welding torch (e.g., drive wheels, wire guides, contact tips, gas nozzles, gas diffusers, etc.) so that they can be stored and secure in a convenient and easily accessible position. Hatches may also be equipped with wear plates on the outer surface of the hatches. These wear plates may be removably coupled to the hatches and may allow the wire feeder to be mounted horizontally on its side (ie, one of the hatches) without the outer surfaces of the hatches contacting a supporting surface. This reduces the likelihood of the hatches being damaged (eg scratched, dented, etc.) while the wear plates can be easily replaced if necessary. Additionally, the wheeled cart can be connected to the hatches when the wear plates are removed, allowing the wire feeder to be turned on its side and moved to the desired location. Placing the wire feeder horizontally on its side is more stable and less likely to tip over. This position also makes it easier for the operator to position the wire feeder under obstacles and is more ergonomic for changing the welding wire spool.

[0009] The wire feeder disclosed herein further includes a stress relief device that reduces stress on cables running into the wire feeder, as well as connectors to which the cables are connected within the wire feeder.

[0010] In addition, the wire feeder is equipped with a replaceable cable connector that can be easily replaced with a different type of cable connector depending on which type of connector is compatible with the torch cable used for the welding operation.

[0011] The wire feeder is equipped with an inexpensive control panel that can be easily moved depending on the orientation of the wire feeder.

[0012] In addition, the wire feed mechanism is equipped with easily removable wire guides. More specifically, the wire guides can be quickly and easily removed from the wire feeder without the use of tools. Wire guides can also be securely mounted inside the wire feeder without the use of tools. This allows the wire guides to be replaced when they wear out, or to be replaced with different wire guides that are better suited to the size, type and/or material of the filler wire selected for use by the welder.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 illustrates a schematic diagram of a welding machine.

[0014] FIG. 2A illustrates a front perspective view of the wire feed mechanism of the welding machine shown in FIG. 1.

[0015] FIG. 2B illustrates a rear perspective view of the wire feeder shown in FIG. 2A.

[0016] FIG. 3A illustrates a front view of the wire feeder shown in FIG. 2A.

[0017] FIG. 3B illustrates a rear view of the wire feeder shown in FIG. 2A.

[0018] FIG. 3C illustrates a first side side view of the wire feeder shown in FIG. 2A.

[0019] FIG. 3D illustrates a second side view of the wire feeder shown in FIG. 2A.

[0020] FIG. 3E illustrates a top view of the wire feeder shown in FIG. 2A.

[0021] FIG. 3F illustrates a bottom view of the wire feeder shown in FIG. 2A.

[0022] FIG. 4A illustrates a cross-section of the mounting structure of the wire feeder shown in FIG. 2A.

[0023] FIG. 4B illustrates a perspective view of a wire feeder mounted on a cart using this mounting structure.

[0024] FIG. 5A illustrates a perspective view of the first side of the wire feeder shown in FIG. 2A, wherein the first hatch is in an open position providing access to components located adjacent to the first side of the wire feeder.

[0025] FIG. 5B illustrates a perspective view of the second side of the wire feeder shown in FIG. 2A, where the second hatch is in an open position, providing access to components located adjacent to the second side of the wire feeder.

[0026] FIG. 6A illustrates a perspective view of the outside of the first hatch shown in FIG. 4A.

[0027] FIG. 6B illustrates a perspective view from the inside of the first hatch shown in FIG. 6A.

[0028] FIG. 6B illustrates a perspective view from the inside of the first hatch shown in FIG. 6A.

[0029] FIG. 6C illustrates a perspective view from the inside of the first hatch shown in FIG. 6B, with the first hatch inner panel removed.

[0030] FIG. 6D illustrates an inside view of the inner side of the inner panel removed from the first hatch shown in FIG. 6A.

[0031] FIG. 6E illustrates the storage compartments of the first hatch shown in FIG. 6A.

[0032] FIG. 6F illustrates a perspective view of the second side of the wire feeder shown in FIG. 2A, where the wear plates have been removed from the second hatch.

[0033] FIG. 7A illustrates an exploded perspective view of the housing parts of the wire feeder shown in FIG. 2A.

[0034] FIG. 7B illustrates a cross-section of the second side of the wire feeder shown in FIG. 2A.

[0035] FIG. 7C illustrates a cross-sectional perspective view of a first side of the wire feeder shown in FIG. 2A.

[0036] FIG. 7C illustrates a cross-sectional perspective view of the front side of the wire feeder shown in FIG. 2A.

[0037] FIG. 8A illustrates a perspective view of the stress relief device relative to the rear side of the wire feeder shown in FIG. 2A.

[0038] FIG. 8B illustrates a front perspective view of the strain relief device shown in FIG. 8A.

[0039] FIG. 8C illustrates a rear perspective view of the strain relief device shown in FIG. 8A.

[0040] FIG. 8D illustrates an exploded view of the front side of the components of the strain relief device shown in FIG. 8A.

[0041] FIG. 8E illustrates an exploded view of the front side of the components of the strain relief device shown in FIG. 8A.

[0042] FIG. 8F illustrates a perspective view of the strain relief device shown in FIG. 8A connected to the connecting cable.

[0043] FIG. 9A illustrates a perspective view of the front side control panel of the wire feeder shown in FIG. 2A.

[0044] FIG. 9B illustrates a rear perspective view of the base member of the control panel shown in FIG. 9A.

[0045] FIG. 9C illustrates an exploded view of the components of the control panel shown in FIG. 9A.

[0046] FIG. 9D illustrates the control panel shown in FIG. 9A mounted on the front side of the wire feeder shown in FIG. 2A, in a different configuration.

[0047] FIG. 10A illustrates a perspective view of the wire feeder shown in FIG. 2A.

[0048] FIG. 10B illustrates an exploded view of the front side of the wire feeder shown in FIG. 10A.

[0049] FIG. 10C illustrates a perspective view of the front side of the wire feeder shown in FIG. 10A, wherein the first wire feeder housing portion is separated from the second wire feeder housing portion.

[0050] FIG. 11 illustrates a perspective view of the sliding actuators and inlet and outlet guides of the wire feeder shown in FIG. 10A.

[0051] FIG. 12A illustrates an exploded view of the first side of the intermediate wire guide of the wire feeder shown in FIG. 10A.

[0052] FIG. 12B illustrates an exploded perspective view of the second side of the intermediate wire guide shown in FIG. 12A, which is inserted into the wire feeder shown in FIG. 10A.

[0053] FIG. 12C illustrates a perspective view of a second embodiment of an intermediate wire guide.

[0054] FIG. 12D illustrates a perspective view of a third embodiment of an intermediate wire guide.

[0055] FIG. 13A illustrates a perspective view of a second embodiment of the guide stop mechanism relative to the wire feeder shown in FIG. 10A, in which the latch is in the locked position.

[0056] FIG. 13B illustrates a cross-section of a second embodiment of the guide lock mechanism shown in FIG. 13A, in which the latch is in the locked position.

[0057] FIG. 13C illustrates a perspective view of a second embodiment of the guide lock mechanism shown in FIG. 13A, in which the latch is in the unlocked position.

[0058] FIG. 13D illustrates a cross-section of a second embodiment of the guide lock mechanism shown in FIG. 13C, in which the latch is in the unlocked position.

[0059] FIG. 14A illustrates a perspective view of the front side of the wire feeder shown in FIG. 10A, where the replacement cable connector is connected to the output side of the wire feeder.

[0060] FIG. 14B illustrates a perspective view of the rear side of the wire feeder shown in FIG. 10A, where the replaceable cable connector shown in FIG. 14A is connected to the output side of the wire feeder.

[0061] FIG. 14C illustrates an exploded view of an assembly of two types of replacement cable connectors and their connection to the output side of the wire feeder shown in FIG. 10A.

[0062] FIG. 14D illustrates a perspective view of the front side of the wire feeder shown in FIG. 2A, wherein one of the replaceable cable connectors is at least partially accessible through a connection panel on the front side of the wire feeder.

[0063] FIG. 14E and 14F illustrate front views of two types of replacement cable connectors and the orientation of the torch connector socket relative to the replacement cable connectors.

[0064] FIG. 15A illustrates a perspective view of a cart that can be attached to any of the wire feeder hatches shown in FIG. 2A.

[0065] FIG. 15B illustrates a front perspective view of the wire feeder shown in FIG. 2A, with the cart shown in FIG. 15A connected to the second hatch.

[0066] The same reference numerals have been used to designate the same elements throughout the present specification.

DETAILED DESCRIPTION OF THE INVENTION

[0067] FIG. 1 illustrates a schematic drawing of one embodiment of a welding system 10 that drives, controls, and supplies materials for a welding operation. The welding system 10 includes a power source 20 having a control panel 22 from which a welding operator can control the welding output voltage, welding current, gas flow, and/or other parameters of the welding operation. The control panel 22 may include input or interface devices that a welding operator can use to adjust welding parameters (eg, voltage, current, etc.). The power source 20 may be connected to a gas source 30, which may be either external to the power source 20 (as shown in FIG. 1) or internal to the power source 20. The gas source 30 may provide shielding gas for the welding operation.

[0068] As shown in FIG. 1, the welding system 10 also includes a wire feeder 40 that is coupled to a power source 20 via at least one interconnect cable 60. The interconnect cable 60 may at least provide welding power (i.e., voltage and current) to the feeder 40 wire. In those embodiments where the gas source 30 is connected to the power source 20, the connecting cable 60 may further be configured to supply shielding gas to the wire feeder 40. In additional embodiments, the connecting cable 60 may be configured to provide bidirectional communication (eg, control and feedback signals) and/or cooling water between the power source 20 and the wire feeder 40.

[0069] The wire feeder 40 may be configured to supply welding wire to the welding gun or welding torch 50 for use in a welding operation via the torch cable 62 . The wire feeder 40 may also be configured to supply welding power and shielding gas to the welding torch 50 via the torch cable 62 . Like the interconnect cable 60, the torch cable 62 may also provide bidirectional communication (eg, control and feedback signals) between the welding torch 50 and the wire feeder 40. In some embodiments, wire feeder 40 may also include a control panel 42 that allows the user to set one or more wire feed parameters, such as wire feed speed. In some embodiments, where the interconnect cable 60 is configured to provide bidirectional communication (e.g., control and feedback signals) between the power source 20 and the wire feeder 40, the control panel 42 may allow the welding operator to control other welding parameters (e.g., voltage , current, etc.) usually regulated at the power supply 20. As further illustrated in FIG. 1, in some embodiments, the gas source 30 may be directly coupled to the wire feeder 40 rather than the power source 20. In exemplary embodiments, wire feeder 40 includes a variety of internal components, including those described in more detail herein.

[0070] The welding torch 50 is configured to perform a welding operation on the workpiece 70 when controlled by a welder. As illustrated, welding torch 50 may include a control panel 52 that may include input or interface devices that an operator may use to perform a welding operation on workpiece 70 using welding torch 50. In those embodiments where cable 62 The torch is configured to provide bidirectional communication (eg, control and feedback signals) between the wire feeder 40 and the welding torch 50, the control panel 52 allows the welder to control welding parameters (eg, voltage, current, etc.) and wire feed parameters (eg, wire feed speed, etc.) typically adjustable at the power source 20 and wire feeder 40, respectively.

[0071] As shown in FIG. 1, the power source 20 is also coupled to the workpiece 70 via a return cable 64. The return cable 64 completes the circuit between the power source 20 and the welding torch 50 during a welding operation performed on the workpiece 70.

[0072] It should be noted that although the illustrated embodiments are described in the context of a MIG welding system, the features of the present invention can be used with a variety of other suitable welding systems and processes that use continuously fed wire.

[0073] In FIG. 2A, 2B, 3A, 3B, 3C, 3D, 3E and 3F show an exemplary embodiment of the wire feeder 40. The wire feeder 40 may have a general shape that is a substantially rectangular parallelepiped with a front side 100, a back side 102 opposite the front side 100, a top side 104 extending from the front side 100 to the back side 102, and a bottom side 106 opposite a top side 104 that also extends from a front side 100 to a rear side 102. The wire feeder 40 further includes a first side 108 extending between the front and rear sides 100, 102, and top and bottom sides 104, 106. The wire feeder 40 The wire feed also includes a second side 110 opposite the first side 108 and also extending between the front, rear, top and bottom sides 100, 102, 104, 106. Front side 100, back side 102, top side 104, bottom side 106, the first side 108 and the second side 110, as described and illustrated herein, collectively form a housing 120 housing various components of the wire feeder 40.

[0074] As best illustrated in FIG. 2A and 3A, the front side 100 of the wire feeder 40 includes a control panel 130, a first connection panel 131, and a second connection panel 137. The control panel 130 is configured to control various wire feeding parameters of the wire feeder 40. In some embodiments, the control panel 130 may also be configured to adjust and display various welding parameters (e.g., voltage, current, wire feed speed, etc.), including those typically set and adjusted at the power source 20 of conventional welding systems. . The control panel 130 may also be configured to display memory settings, various warnings and error codes, and gas flow control parameters. The first connection panel 131, as described in more detail below, includes a removable cover panel 132 and an opening 133 for receiving a connector of a torch cable 62 for connecting the welding torch 50 to the wire feeder 40. More specifically, and as described in more detail below, a removable cable connector 134 is located within an opening 133 of the cover removable panel 132, where the removable cable connector 134 may be operably connected to a torch cable 62. The first connection panel 131 may also include an auxiliary connector 135 and an auxiliary connector 136. The auxiliary connector 135 may be configured to receive a connector for an auxiliary device (eg, a push-pull welding torch) and send/receive communication and command signals to/from the auxiliary device. The accessory connector 136 may be connected to an accessory cable that may provide an electrical signal (eg, a weld start/stop switching signal) when, as explained in more detail below, the replacement cable connector 134 installed is a TWECO connector. The second connection panel 137 of the front side 100 of the wire feeder 40 includes a pair of water connectors 138(1), 138(2), which can be configured as cooling water supply and cooling water return connectors, respectively, for water-cooled MIG guns. As illustrated, the second connection panel 137 may also include a rotating detector block 139, where rotation of the rotating detector block 139 can be used to determine whether a hose is connected to the cooling water supply outlet connector 138(1). In some embodiments, the rotary detector block 139 may be used to measure the cooling output flow requirements of an attached accessory, where the output flow requirements may be determined by the amount of rotation of the rotary detector block 139.

[0075] As best illustrated in FIG. 2B and 3B, the rear side 102 of the wire feeder 40 includes a strain relief device 140, a rear control and interface panel 142, and a rear wire input connector 144. A stress relief device 140 extends outwardly from the rear side 102 adjacent the bottom side 106 and the second side 110. As described in more detail below, the stress relief device 140 may be configured to relieve stresses generated on a connecting cable 60, which may internally contain a welding power cable, communication signal cable, shielding gas cable, cooling water supply cable and cooling water return cable. As illustrated, rear control and interface panel 142 may be located adjacent the top side 104 of wire feeder 40, and may include an accessory receptacle 146 that may be configured to connect to and provide power to an accessory (such as an auxiliary arc welding torch). in a protective environment or a manual arc welding torch), a secondary output 148 that can serve as a ground for the wire feeder 40 for specific welding operations, and a pair of adjustment knobs 149 that can be configured to control power to accessories connected to the outputs 146, 148 or other optional accessories located inside the wire feeder 40 (eg, an internal heater located inside the wire feeder 40). The rear wire entry connector 144 extends outward from the rear side 102 of the wire feeder 40 adjacent the bottom side 106 and the first side 108 of the wire feeder 40 . The rear wire input connector 144 may be configured to connect to an external welding wire spool so that the wire feeder 40 can supply welding wire from the external welding wire spool to the welding torch 50.

[0076] As best illustrated in FIG. 2A, 2B, 3C, 3D and 3E, the top side 104 of the wire feeder 40 is equipped with a main handle 150 and two additional handles 152 (1), 152 (2). The main handle 150 may extend upward from the surface of the top side 104 and may extend along the wire feeder 40 between the front side 100 and the back side 102. In addition, the main handle 150 may be located on the top side 104 so that it is equidistant from the first side 108 and the second side 110 of the wire feeder 40. An additional handle 152(1) may be located on the top side 104 of the wire feeder 40 at the junction or intersection of the top side 104 and the front side 100, while an additional handle 152(2) may be located on the top side 104 of the wire feeder 40 at the junction or intersection of the top side 104 and the back side 102. While the main handle 150 may extend generally upward from the top side 104 of the wire feeder 40, additional handles 152(1), 152(2) may extend upward from the top sides 104 and outward from the front and rear sides 100, 102, respectively. The main handle 150 and additional handles 152(1), 152(2) make the wire feeder 40 portable, allowing the welder to more easily move the wire feeder 40, as well as install the wire feeder 40 in different orientations.

[0077] As further illustrated in FIG. 3F, the lower side 106 of the wire feeder 40 is provided with grippers 154(1), 154(2). The first grip 154(1) may be located on the surface of the housing 120 on the underside 106 of the wire feeder 40 adjacent the front side 100 of the wire feeder 40. The second gripper 154(2) may be located on the surface of the housing 120 on the underside 106 of the wire feeder 40 adjacent the rear side 102 of the wire feeder 40. The grips 154(1), 154(2) may be recesses located inside the bottom side 106 of the wire feeder 40. The grips 154(1), 154(2) in combination with the main handle 150 and additional handles 152(1), 152(2) make it easier for the welder to transport and position the wire feeder 40.

[0078] As shown in FIG. 3F and Fig. 4A, the wire feeder 40 includes a mounting structure 160 that can be generally located on the bottom side 106 of the wire feeder 40 and allows the wire feeder 40 to be more easily installed on a mounting platform or stand. As illustrated, mounting structure 160 includes an elongate channel 162 (illustrated in Figs. 3F and 4A), an opening 164 (illustrated in Figs. 3F and 4A), and a vertical receiver 166 (illustrated in Fig. 4A) that extends from the opening. 164 into the interior 300 of the housing 120. An elongated channel 162 is located on the surface of the housing 120 on the underside 106 and extends longitudinally along the underside 106. The elongated channel 162 includes a first end 168 and a second end 169, where the first end 168 is located toward the front side. 100 of the wire feeder 40, and the second end 169 is located closer to the rear side 102 of the wire feeder 40. As illustrated in FIG. 3F, the elongated channel 162 is located on the surface of the housing 120 on the lower side 106 so that it is equidistant from the first and second sides 108, 110 of the wire feeder 40. The elongated channel 162 may have side walls that gradually extend through rounded edges from the elongated channel 162 to the surface of the housing 120 on the underside 106 of the wire feeder 40. In addition, the opening 164 may be located on the surface of the housing 120 on the lower side 106 such that the opening 164 is at least partially aligned with the elongated channel 162. The opening 164 may be in fluid communication with a vertical receiver 166 that extends upward from the lower sides 106 into the internal cavity 300 of the wire feeder 40. The opening 164 and vertical receiver 166 may be sized and shaped to receive the end of a mounting post or other mounting structure. In some embodiments, the opening 164 may be substantially circular and the vertical receptacle 166 may be substantially cylindrical. In other embodiments, the hole 164 and vertical receptacle 166 may have other shapes.

[0079] The mounting structure 160 may allow a welder to easily and efficiently install the wire feeder 40 onto a mounting structure (eg, a wheeled cart having a mounting post, such as that illustrated in FIG. 4B). The welder can lift the wire feeder 40 onto the end of the mounting post so that the underside 106 of the wire feeder 40 rests on the end of the mounting post. The welder can then move the wire feeder 40 laterally relative to the end of the mounting post so that the end of the mounting post slides against the underside 106 of the wire feeder 40 toward either the first side 108 or the second side 110. The welder can move the wire feeder 40 from side to side until the end of the mounting post is engaged in the elongated channel 162. After the end of the mounting post is engaged in the elongated channel 162, the welder can longitudinally slide the wire feeder 40 relative to the end of the mounting post so that the end of the mounting post slides along the elongated channel 162 between the first end 168 and the second end 169 of the elongated channel 162. The welder can move the wire feeder 40 longitudinally until the end of the mounting post is aligned with the hole 164. Once the end of the mounting post is aligned with the hole 164, the end of the mounting post is aligned with the hole 164. can be inserted into the vertical slot 166 through the hole 164 by lowering the wire feeder 40 onto the mounting post. Inserting the end of the mounting post into the vertical slot 166 secures the wire feeder to the mounting post. Thus, the mounting structure 160 allows the welder to easily install the wire feeder onto the mounting post based on feel (i.e., whether the end of the mounting post fits into the elongated channel 162 or aligns with the hole 164), rather than having to judge the alignment of the hole in the bottom of the wire feeder 40 with the end of the mounting post.

[0080] As illustrated in FIG. 2A, 2B, 3C, 3D, 5A and 5B, the wire feeder 40 includes a first hatch 170 and a second hatch 180. The first hatch 170 is located on the first side 108 of the wire feeder 40, and the second hatch 180 is located on the second side 110 of the device. 40 wire feeds. As best illustrated in FIG. 5A, the first hatch 170 is rotatably coupled to the wire feeder 40 near the intersection of the first side 108 and the top side 104 and is rotatable about an axis A-A between a closed position (shown in FIGS. 2B and 3C) and an open position (shown in Fig. 5A). Likewise, the second hatch 170 is rotatably coupled to the wire feeder 40 near the intersection of the second side 110 and the top side 104 and is rotatable about an axis B-B between a closed position (shown in FIGS. 2A and 3D) and an open position (shown in Fig. 5B). When the hatches 170, 180 are in open positions, they provide access to the internal cavity 300 of the wire feeder 40. More specifically, the first hatch 170 in the open position exposes a first opening 122 in the housing 120 on the first side 108 of the wire feeder 40, while the second hatch 180 in the open position exposes a second opening 124 in the housing 120 on the second side 110 of the wire feeder 40 .

[0081] In FIG. 6A, 6B, 6C, 6D, 6E and 6F illustrate separate views of the first hatch 170 (FIGS. 6A, 6B, 6C, 6D and 6E) as well as a perspective view of the wire feeder 40 showing the second hatch 180 (FIG. 6F). While Fig. 6A, 6B, 6C, 6D and 6E illustrate the first hatch 170, discussion of FIG. 6A, 6B, 6C, 6D and 6E also refer to the second hatch 180, since the two hatches 170, 180 may be almost identical to each other. Likewise, while FIG. 6F illustrates the second hatch 180, discussion of FIG. 6F also refers to the first hatch 170.

[0082] As illustrated in FIG. 6A, 6B, 6C, 6D, and 6E, the first hatch 170 has an outer side 200 that forms the majority of the first side 108 of the wire feeder 40, and an opposing inner side 210. The first hatch 170 also includes a top edge 230, a bottom edge 240 opposite the top edge 230, a first side edge 250 that extends from the top edge 230 to the bottom edge 240, and a second side edge 260 that extends from the top edge 230 to the bottom edge 240 and opposite the first side edge 250. As illustrated, the top edge 230 includes a pair of hinge elements 232(1), 232(2) that extend from the top edge 230. Hinge elements 232(1), 232(2) are spaced apart along the top edge 230, with the first hinge element 232(1) is located closer to the first side edge 250, and the second hinge member 232(2) is located closer to the second side edge 260. As shown in FIG. 2A, 2B, 3E, 5A and 5B, the hinge members 232(1), 232(2) may fit into recesses 190, 192 that are located in the housing 120 primarily on the top side 104 of the wire feeder 40. The recesses 190(1), 190(2) may be located on the top side 104 of the wire feeder 40 adjacent the first side 108, while, as best illustrated in FIG. 5A, they extend at least partially down the first side 108 of the housing 120 of the wire feeder 40. Likewise, recesses 192(1), 192(2) may be located on the top side 104 of the wire feeder 40 adjacent the second side 110, while, as best illustrated in FIG. 5B, they extend at least partially down the second side 110 of the housing 120 of the wire feeder 40. As best illustrated in FIG. 2B and 5A, the recesses 190(1), 190(2) are spaced apart from each other so that the recesses 190(1), 190(2) receive the hinge elements 232(1), 232(2) of the first hatch 170. Hinge elements 232(1), 232(2) allow the first hatch 170 to be pivotally coupled to the body 120 of the wire feeder 40 at the intersection of the first side 108 and the top side 104 of the wire feeder 40. In addition, the axis A-A about which the first hatch 170 rotates passes through the recesses 190(1), 190(2) and the hinge members 232(1), 232(2).

[0083] As best illustrated in FIG. 2B, the recesses 190(1), 190(2) are sized such that when the first hatch 170 is in the closed position, the hinge members 232(1), 232(2) are located within a portion of the recesses 190(1), 190(2). which are located on the first side 108 of the wire feeder housing 120 such that the hinge members 232(1), 232(2) are flush with that portion of the housing 120 that surrounds the recesses 190(1), 190(2). The hinge members 232(1), 232(2), which are flush with the housing 120 when the first hatch 170 is in the closed position, provide protection for the hinge members 232(1), 232(2), making them less accessible to direct impact.

[0084] In addition to this, as best illustrated in FIG. 2A and 2B, recesses 190(1), 190(2) extend to the center of the top side 104 of the body 120 of the wire feeder 40 from the hinge members 232(1), 232(2) (i.e., recesses 190(1), 190(2 ) extend partially through the top side 104 of the housing 120 to the second side 110). These portions of the recesses 190(1), 190(2) allow the first hatch 170 to rotate more than 180 degrees about an axis A-A from a closed position to an open position where, in the open position, the outer side 200 of the first hatch 170 abuts the main handle 150 located on the upper surface 108 of the wire feeder 40. In addition, when the wire feeder 40 is positioned on the second side 110 in a horizontal configuration (that is, the second side 110 is placed on a support surface), the first hatch 170 can be rotated more than 180 degrees about an axis A-A from a closed position to an open position, where, in the open position, the lower edge 240 of the first hatch 170 abuts the support surface. By abutting the first hatch 170 against objects (eg, the main handle 150 or a support surface) when in the open position, stresses and strains on the hinge members 232(1), 232(2) are reduced.

[0085] The recesses 192(1), 192(2) may be substantially similar to the recesses 190(1), 190(2), and may provide the second hatch 180 with the same features as those provided to the first hatch 170 by the recesses 190( 1), 190(2).

[0086] As best illustrated in FIG. 6A and 6B, the first hatch 170 also includes a pair of latches 242(1), 242(2) that may be configured to lock the first hatch 170 in the closed position illustrated in FIG. 2B and 3C. The first latch 242(1) is located at the intersection or connection of the lower edge 240 with the first side edge 250, while the second latch 242(2) is located at the intersection or connection of the lower edge 240 with the second side edge 260. Thus, the latch 242(1 ), 242(2) are on opposite sides of the lower edge 240 relative to each other. The valves 242(1), 242(2) may be rotatably connected to the first hatch 170. In addition, the valves 242(1), 242(2) may be configured to coincide with mating portions 126(1), 126(2), respectively, of the housing 120 of the wire feeder 40 (shown in FIG. 5A). Thus, when the first hatch 170 is in the closed position, the first latch 242(1) may engage and be operably engaged with the first mate 126(1). Likewise, the second latch 242(2) may engage the second mate 126(2) and may be configured to operatively engage therewith when the first hatch 170 is in a closed position. When the valves 242(1), 242(2) are positioned within and engaged with the mating portions 126(1), 126(2), respectively, the first hatch 170 is locked in the closed position. In some embodiments, the first hatch 170, in the closed position, may form a substantially airtight or airtight seal with the opening 122 of the housing 120. The welder may rotate the valves 242(1), 242(2) around the first hatch 170 to withdraw the valves 242(1), 242(2) from the mating parts 126(1), 126(2), respectively, which will allow the first hatch 170 to be rotated from a closed position to an open position around axis A-A.

[0087] As best illustrated in FIG. 6A, the outer side 200 of the first hatch 170 includes two protruding wear plates 202(1), 202(2) that are removably attached to the first hatch 170 and extend externally from the surface of the outer side 200. The first wear plate 202(1) may be located adjacent the top edge 230, while the second wear plate 202(2) may be located adjacent the bottom edge 240. The wear plates 202(1), 202(2) may extend substantially along the outside 200 of the first hatch 170 from the first side edge 250 to the second side edge 260. When the first hatch 170 is in the closed position, the wire feeder 40 can be placed on the support surface with its first side 108, and the wear plates 202(1), 202(2) provide the structure, which contacts the support surface and supports the wire feeder 40 on the support surface. Thus, when the wire feeder 40 is placed with the first side 108 down on the support surface, the wear plates 202(1), 202(2) separate the outer side 200 from the support surface. The wear plates 202(1), 202(2) may reduce wear of the first hatch 170 by separating the outer side 200 of the first hatch 170 from the supporting surface when the wire feeder 40 is installed in a horizontal orientation with the first hatch 170 downward. In addition, the wear plates 202(1), 202(2) may be made of a composite material that allows the wear plates 202(1), 202(2) to be wear resistant (i.e., resistant to abrasion, dents, scratches, etc. .). In some embodiments, this composite material may also allow the wear plates 202(1), 202(2) to serve as low friction surfaces that the welder can use to move the wire feeder 40 across support surfaces.

[0088] The wear plates 202(1), 202(2) may be removably coupled to the exterior 200 of the first hatch 170 using a set of fasteners (e.g., screws) inserted into mounting holes 204 located in the wear plates 202(1). , 202(2). Fig. 6F illustrates wear plates 202(1), 202(2) removed from the outside 200 of second hatch 180. As illustrated, removal of wear plates 202(1), 202(2) from first hatch 170 or second hatch 180 exposes a set of outer side fasteners 206 that are configured to align with fastener holes 204 of wear plates 202(1), 202(2) and a set of mounting holes 208. As explained in more detail below, the cart 1500 can be connected to any of the hatch panels 170, 180 through the mounting holes 208 when the wear plates 202(1), 202(2) are removed.

[0089] As shown in FIG. 6A and 6B, the first hatch 170 further includes a viewing window 212. The viewing window 212 extends through the first hatch 170 from the outer side 200 to the inner side 210. The viewing window 212 may be located adjacent the first side edge 250 and may be located at a distance from a top edge 230 and a bottom edge 240. In addition, the viewing window 212 may be at least partially translucent so that the welder can see the interior cavity 300 of the wire feeder 40 when the first hatch 170 is in the closed position. (In other words, the welder can see the internal cavity 300 without having to open the first hatch 170). More specifically, the viewing window 212 provides a view of the filler wire and/or the filler wire spool 320 so that the welder can easily and quickly determine the amount of filler wire that remains inside the wire feeder 40 .

[0090] As best illustrated in FIG. 6B, 6C and 6D, the first hatch 170 includes an internal storage compartment 214 adjacent the second side edge 260. The internal storage compartment 214 may include a series of openings 216, 218, 220, 222, 224, 226 located in the surface of the internal side 210 of the first hatch 170, as well as an intermediate storage organizer 272 located in the intermediate space 270 that is located between the outer side 200 and the inner side 210 of the first hatch 170. As illustrated in FIG. 6B, the internal storage compartment 214 includes six storage openings 216, 218, 220, 222, 224, 226 that are in close proximity to each other. The first and second storage openings 216 and 218 may be configured to receive and store replacement drive wheels 818 (see, for example, FIGS. 6E and 10A) of the wire feeder 310, as will be described in more detail below. As illustrated, the first and second storage openings 216 and 218 may be elongated horizontal openings that are widest at their middle or center portion. In addition, the third and fourth storage openings 220, 222 may be at least partially located between the first and second storage openings 216, 218, and may be configured to store the tubular wire feed guides 1000, 1100, 1200, as will be described in more detail below (see, for example, Figs. 6E, 10A-10C, 11 and 12A-12D). The third storage opening 220 may be an elongated vertical opening with a middle or center portion that is wider than the end portions, while the fourth storage opening 222 may have a left portion that is shorter in height than the right portion. The fifth and sixth storage openings 224, 226 may be located substantially adjacent the first and second storage openings 216, 218, and may be configured to receive and store contact tips 290 of the welding torch 50, as shown in FIG. 6E. As illustrated, the fifth and sixth storage openings 224, 226 may be substantially rectangular in shape.

[0091] As best illustrated in FIG. 6C, where a panel on the inside 210 of the first hatch 170 is removed to reveal an intermediate space 270 of the first hatch 170 and an intermediate storage organizer 272, and as illustrated in FIG. 6D, where the intermediate storage organizer 272 is positioned against the inner surface of a panel located on the inner side 210 of the first hatch 170, the intermediate storage organizer 272 is provided with a number of cutouts and slits. More specifically, the intermediate storage organizer 272 includes three cutouts and six slits. The first and second cutouts 274, 276 may be elongated horizontal cutouts having rounded and wavy side walls that create three segmented regions of the cutouts 274, 276 configured to receive drive wheels 818. The third cutout 278 may be a vertically oriented cutout located between the first and second cutouts 274, 276. m 278 may have a rectangular shaped middle portion with elongated slits extending up and down from the rectangular middle portion. The first pair of slits 280 may be located in the intermediate storage organizer 272 adjacent the third cutout 278 and between the first and second cutouts 274, 276. The second pair of slits 282 may be located in the intermediate storage organizer 272 adjacent the first cutout 274 while how a third pair of slits 284 may be located in the intermediate storage organizer 272 adjacent the second cutout 276. Additionally, the intermediate storage organizer 272 may be made of a deformable foam or foam-like material.

[0092] As best illustrated in FIG. 6D, the intermediate storage organizer 272 is shaped such that the cutouts and slits 274, 276, 278, 280, 282, 284 are aligned with the openings 216, 218, 220, 222, 224, 226 of the internal storage compartment 214 to facilitate insertion of objects. into openings 216, 218, 220, 222, 224, 226 and storing these objects in cutouts and crevices 274, 276, 278, 280, 282, 284 of the intermediate storage organizer 272. As shown in FIG. 6D, the first and second cutouts 274, 276 are aligned with the first and second openings 216, 218, respectively. In addition, the middle segmented area of the first cutout 274 is aligned with the wider central portion of the first opening 216, while likewise the middle segmented area of the second cutout 276 is aligned with the wider central portion of the second opening 218. This allows drive wheels 818 to be inserted into the middle or the center portion of the first and/or second openings 216, 218, and then slide toward one of the ends of the first and second openings 216, 218 for storage. The drive wheels 818 may have a diameter greater than the width of the end portions of the first and second openings 216, 218, but the end segmented regions of the first and second cutouts 274, 276 may be sized to receive the drive wheels 818. The combination of the width of the end portions of the first and second openings 216, 218, which is smaller than the diameter of the drive wheels 818, and the wavy side walls of the first and second cutouts 274, 276 defining segmented areas, secures the drive wheels 818 at the ends of the first and/or second openings 216, 218. In other words, the panel defining the inner side 210 of the first hatch 170, holds the drive wheels 818 in the inner storage compartment 214 in a direction perpendicular to the plane in which the panel forming the inner side 210 is located. At the same time, the segmented areas of the intermediate storage organizer 272 support the drive wheels 818 in the inner storage compartment 214 in a direction parallel to the plane in which the panel defining the inner side 210 is located. This combination is effective in preventing the drive wheels 818 from falling out of the inner storage compartment 214, especially when the first hatch 170 is rotated to a closed position. The storage of the drive wheels 818 is shown in FIG. 6E.

[0093] As further illustrated in FIG. 6D, the third cutout 278 of the intermediate storage organizer 272 is substantially equal in size and shape to the third storage opening 220. The third storage opening 220 is configured to receive an intermediate wire guide 1200 (best illustrated in FIGS. 12A, 12B, 12C and 12D and discussed in more detail below) of the wire feeder 310 (FIG. 10A). As illustrated in FIG. 6E, the intermediate wire guide 1200 may be held in the third storage hole 220 by the interaction of tabs located on the living hinges of the intermediate wire guide 1200 with the edges of the third storage hole 220. In other words, the interaction of the tongues of the intermediate wire guide 1200 with the edges defining the third storage opening 220 holds the wire guide 1200 inside the storage compartment 214 in a direction perpendicular to the plane in which the panel defining the inner side 210 is located. At the same time, the shape of the third cutout 278 of the intermediate storage organizer 272 holds the intermediate wire guide 1200 inside the storage compartment 214 in a direction parallel to the plane in which the panel forming the inner side 210 is located. This combination is effective in preventing the intermediate wire guide 1200 from falling out of the internal storage compartment 214 , especially when the first hatch 170 is rotated to the closed position.

[0094] FIG. 6D also illustrates that the first pair of slits 280 may be offset from the fourth storage opening 222 but in fluid communication with the fourth storage opening 222. More specifically, when the intermediate storage organizer 272 is aligned with the openings 216, 218, 220, 222, 224, 226 of the storage compartment 214, the slots 280 extend from the leftmost portion of the fourth storage opening 222 behind the panel forming the inside 210 of the first hatch 170 Thus, the inlet and outlet wire guide tubes 1000, 1100 (best illustrated in Fig. 11, and discussed in more detail below) can be inserted into the fourth storage hole 222 through the rightmost portion of the fourth storage hole 222, and then slid into the slots 280. The first pair of slots 280 may be sized and shaped to frictionally receive and retain inlet and outlet wire guide tubes 1000, 1100, as illustrated in FIG. 6E. In other words, with the inlet and outlet wire guide tubes 1000, 1100 located generally behind the panel defining the inner side 210 of the first hatch 170, the panel forming the inner side 210 retains the inlet and outlet wire guide tubes 1000, 1100 within the storage compartment 214 in a direction perpendicular to the plane in which the panel forming the inner side 210 is located. At the same time, the first pair of slits 280, which frictionally receive the inlet and outlet wire guide tubes 1000, 1100, serve to hold them in the intermediate storage organizer 272 in the direction , parallel to the plane in which the panel forming the inner side 210 is located. This combination is effective in preventing the inlet and outlet wire guide tubes 1000, 1100 from falling out of the inner storage compartment 214, especially when the first hatch 170 is rotated to a closed position.

[0095] Similar to the first pair of slits 280, FIG. 6D further illustrates that the second and third pairs of slits 282, 284 may be offset from the fifth and sixth storage openings 224, 226, respectively, but are in fluid communication with the fifth and sixth storage openings 224, 226, respectively. Similar to the first pair of slots 280 when the intermediate storage organizer 272 is aligned with the openings 216, 218, 220, 222, 224, 226 of the storage compartment 214, the second pair of slots 282 extends from the fifth storage opening 224 behind the panel forming the inside 210 of the first hatch 170. Likewise, a third pair of slots 284 extend from a sixth storage hole 226 behind a panel forming the inside 210 of the first hatch 170. To store contact tips 290 within the fifth and sixth storage holes 224, 226, contact tips 290 may be inserted into the fifth and/or sixth storage openings 224, 226 and then slid into second and/or third pairs of slots 282, 284, respectively. Like the first pair of slots 280 and the inlet and outlet wire guide tubes 1000, 1100, the second and third pairs of slots 282, 284 may be sized and shaped to frictionally receive and retain the contact tips 290. In other words, with the contact tips 290, located generally behind the panel forming the inner side 210 of the first hatch 170, the panel forming the inner side 210 retains the contact tips 290 within the storage compartment 214 in a direction perpendicular to the plane in which the panel forming the inner side 210 is located. At the same time, the second and a third pair of slits 282, 284 frictionally receiving the contact tips 290 serve to retain them in the intermediate storage organizer 272 in a direction parallel to the plane in which the panel forming the inner side 210 is located. This combination is effective in preventing the contact tips 290 from falling out. from the internal storage compartment 214, especially when the first hatch 170 is rotated to the closed position.

[0096] As shown in FIG. 5A and 5B, various components are located within the inner cavity 300 of the housing 120 of the wire feeder 40. Some of these components include a wire feeder 310, a welding wire spool 320, a circulation/cooling fan 330, bus bars 340, as well as other components that are discussed in detail below. As illustrated, the wire feeder 310 and the welding wire spool 320 are located closer to the first side 108 of the wire feeder 40, and are accessible when the first hatch 170 is in the open position. The wire feeder 310 is located in the internal cavity 300 proximal to the front side 100 and bottom side 106 of the wire feeder 310, and may be directly coupled to a replaceable cable connector 134 that is at least partially located within the opening 133 of the first connection panel 132, as described. higher. The welding wire spool 320 may contain welding wire for performing a welding operation, and may be located adjacent the rear side 102 of the wire feeder 40. The filler wire spool 320 may be rotatably mounted on an axis 322 within the inner cavity 300 of the wire feeder 40 such that the filler wire spool 320 can be rotated to unwind the filler wire, which is then fed to the wire feeder 310. The wire feeder 310, as described in more detail below, may be configured to supply welding wire obtained from the welding wire spool 320 or an external wire spool to the welding torch 50 via the torch cable 62.

[0097] As illustrated in FIG. 5B, within the wire feeder 40 is a connection panel 350 that contains a number of connectors and is accessible through the second side opening 124 when the second hatch 180 is in the open position. Connector panel 350 includes a power connector 352, a pair of water connectors 354(1), 354(2), a gas connector 356, and a communications connector 358. Although not illustrated in FIG. 5B, the welding power cable may enter the internal cavity 300 of the housing 120 of the wire feeder 40 through the strain relief device 140 and may be connected to the power connector 352. Likewise, the cooling water supply and return cables that enter the internal cavity 300 of the wire feeder 40 through the stress relief device 140 and can be connected to the water connectors 354(1), 354(2), while the gas supply cable that enters into the internal cavity 300 of the wire feeder 40 through the stress relief device 140, may be connected to the gas connector 356. A communication cable that enters the internal cavity 300 of the wire feeder 40 through the stress relief device 140 may be connected to the communication connector 358 of the connection panel 350.

[0098] With regard to power connector 352, FIG. 5B illustrates that a set of busbars 340 is connected to a power connector 352 such that the busbars 340 are powered by a power source 20 via a power welding cable that ultimately connects to the power connector 352. As shown in FIG. 5B, a set of busbars 340 includes at least a lower busbar 342 and an upper busbar 344. The lower busbar 342 extends downward from the power connector 352 of the backplane 350, while the upper busbar 344 extends upward from the power connector 352 connection panel 350. As described in more detail below, a set of busbars 340 connects to various components within the wire feeder 40 and is configured to supply welding power to the welding torch 50, as well as the power components of the wire feeder 40 and accessories connected to the device 40 wire feeds.

[0099] Although not illustrated in FIG. 5B, each of the other connectors 354(1), 354(2), 356, 358 of the connection panel 350 may also be connected to devices or other connectors within the wire feeder 40 to perform a welding operation. For example, the water connectors 354(1), 354(2) may be connected to the water connectors 138(1), 138(2) of the second connection panel 137 located on the front side 100 of the wire feeder 40 (see FIG. 3A). In addition, the gas connector 356 may be connected to the replacement cable connector 134 so that gas can be supplied to the welding torch 50 when the torch cable 62 is connected to the replacement cable connector 134 in the hole 133 of the first connection panel 131 located on the front side 100 of the device. 40 wire feeds. The communication connector 358 may connect to the control panel 130 of the wire feeder 40, and more specifically, to the printed circuit board (PCB) 720 of the control panel 130 (see FIG. 9C).

[00100] FIG. 7A illustrates an exploded view of the housing 120 of the wire feeder 40. Housing 120 includes an outer housing or frame 400 and an inner housing or frame 410. The inner housing 410 may be shaped and designed to closely match the outer housing 400, as illustrated in FIG. 7B and 7C. The inner housing 410 may be made of materials that are different from the materials of the outer housing 400, such that the inner housing 410 is more rigid than the outer housing 400, while the outer housing 400 may be more flexible and/or resilient than the inner housing 410. In one embodiment, the inner housing 400 may be made of an impact-resistant glass fiber reinforced polyamide compound. In the same embodiment, the outer housing 400 may be made from a combination of materials, including, but not limited to, various types of polyamides and polycarbonate compounds. One option for the polyamide compound forming the outer housing portion 400 may be a glass fiber reinforced, heat stabilized, flame retardant polyamide compound that does not contain halogen and red phosphorus. Another polyamide compound that may form the outer body portion 400 may be similar to the polyamide compound forming the inner body 410, which is a glass fiber reinforced impact resistant polyamide compound. The polycarbonate compound, which may comprise the outer body portion 400, may be a UV stabilized, flame retardant, and impact resistant polycarbonate compound. Both the outer casing 400 and the inner casing 410 may be formed by an injection molding process. This design allows the wire feeder 40 to better withstand the harsh welding conditions it may be subjected to, where the more flexible outer housing 400 is less susceptible to damage (i.e., less susceptible to cracking, dents, and scratches) while the more rigid inner housing 410 provides the rigidity necessary for the body 120 of the wire feeder 40 to maintain its shape. Additionally, this design eliminates the need to construct the housing 120 from heavier materials (eg, steel) that are both rigid and strong enough to withstand damage, which reduces the weight of the wire feeder 40 and allows the wire feeder 40 to be portable.

[00101] As illustrated in FIG. 7A, the outer housing 400 includes side walls 402 that form a front side 100, a rear side 102, a top side 104, and a bottom side 106 of the wire feeder 40. In addition, these four side walls 402 of the outer body 400 collectively form a first hole 122 on the first side 108 of the body 120 of the wire feeder 40 and a second hole 124 on the second side 110 of the body 120 of the wire feeder 40. These four side walls 402 also collectively form a cavity 404 that is sized and shaped to receive the inner housing 410.

[00102] FIG. 7A further illustrates that the inner housing 410, like the outer housing 400, includes four side walls 412 that are adjacent the front side 100, the back side 102, the top side 104, and the bottom side 106 of the wire feeder 40. When the inner housing 410 is located within the cavity 404 of the outer housing 400, these four side walls 412 may collectively define, along with the first and second hatches 170, 180, the inner cavity 300 of the wire feeder 40, where most of the components of the wire feeder 40 are located.

[00103] As further illustrated in FIG. 7A, the inner housing 410 may include a pair of central panels 414, 416 that substantially separate the inner housing 410, and ultimately the inner cavity 300 of the wire feeder 40, into two inner regions. The first internal area (ie, the area that contains the wire feeder 310, the welding wire spool 320, etc.) is located adjacent to the first side 108 of the wire feeder 40 and is accessible to the welder when the first hatch 170 is in the open position. The second internal area (i.e., the area that contains the circulation fan 330, a portion of the busbars 340, the connection panel 350, etc.) is located adjacent to the second side of the wire feeder 110 and is accessible to the welder when the second hatch 180 is in open position. The first center panel 414 may be located adjacent the front side of the inner housing 410, while the second center panel 416 may be located adjacent the rear side of the inner housing 410. The first center panel 414 may be a panel that is connected to or secured to the inner housing 410 by means of fasteners, while the second center panel 416 may be integrally formed with side walls 412 on at least the rear, top and bottom sides of the inner body 410. In addition to dividing the inner cavity 300 into two inner regions, both center panels 414, 416 may provide rigid structural support to the inner housing 410 and ultimately the housing 120 of the wire feeder 40. The center panels 414, 416, and especially the integrally formed second center panel 416, may also provide torsional rigidity to the inner housing 410.

[00104] The side walls 412 of the inner housing 410 further include a series of openings. These openings include an inlet 420 located on the side wall 412 on top of the inner housing 410, and an outlet 422 located at the intersection of the front side side walls 412 and the bottom side of the inner housing 410. FIG. 7A further illustrates that the side wall 412 on the upper side of the inner housing 410 also includes an upper busbar opening 424, while the side wall 412 located on the lower side of the inner housing 410 includes a lower busbar opening 426 .

[00105] As best illustrated in FIG. 7B, 7C, and 7D, when the inner housing 410 is located within the cavity 404 of the outer housing 400, an intermediate space 430 is located between the outer housing 400 and the inner housing 410. This intermediate space 430 may surround the inner housing 410 such that the intermediate space 430 is located adjacent a front side 100, a rear side 102, a top side 104, and a bottom side 106 of the wire feeder 40. The intermediate space 430 may extend continuously around the inner housing 410. The inlet and outlet openings 420, 422 may provide access to the intermediate space 430 from the internal cavity 300 of the wire feeder 40. The upper and lower busbar openings 424, 426 may also provide access to the intermediate space 430 from the internal cavity 430.

[00106] As best illustrated in FIG. 7B and 7D, a lower busbar opening 342 extends from the power connector 352 of the backplane 350 down through the lower busbar opening 426 of the inner housing 410 into an intermediate space 430 adjacent the underside 106 of the wire feeder 40. The lower bus bar opening 342 then extends forward to the front side 100 of the wire feeder 40 through the intermediate space 430. As illustrated in FIG. 7C and 7D, the lower busbar opening 342 also extends through the front side 100 of the wire feeder 40 within the intermediate space 430 to connect to the replaceable cable connector 134. Thus, the lower busbar opening 342 is configured to provide power for the replaceable cable connector 134 so that when the torch cable 62 is connected to the replacement cable connector 134, welding power can be supplied to the welding torch 50 for a welding operation.

[00107] Continuing with FIG. 7B, the upper busbar 344 extends upward from the power connector 352 of the backplane 350 through the upper busbar opening 424 of the inner housing 410 into the intermediate space 430 adjacent the top side 104 of the wire feeder 40. A portion of the upper bus bar 344 located within the intermediate space 430 extends rearwardly from the upper busbar opening 424 down the intermediate space 430 adjacent the rear side 102 of the wire feeder 40 for connection to an additional outlet 146 of the rear control and interface panel 142. Thus , the upper busbar 344 is configured to provide welding power to the auxiliary outlet 146 so that when a welding accessory (for example, an auxiliary shielded arc welding torch or a handheld arc welding torch) is connected to the auxiliary outlet 146, the welding power can fed to the welding accessory.

[00108] Because the busbars 342, 344 pass primarily through the intermediate space 430 generated by the busbars 342, 344, heat is primarily retained in the intermediate space 430 where it can be more easily dissipated through the outer housing 400 to the outside of the supply device 40 wire. The inner housing 410 may further serve to insulate the inner cavity 300 from heat generated by the busbars 342, 344 in the interstitial space 430. Thus, passage of the busbars 342, 344 primarily through the interstitial space 430 reduces the amount of heat that is generated and retained in the inner cavity 430. cavity 300 of the wire feeder 40, which reduces the likelihood of overheating of other wire feeder components located within the cavity 300.

[00109] As best illustrated in FIG. 7C, the intermediate space 430 is further used as part of a closed circuit air circulation path that can be used to cool various components of the wire feeder 40. The circulation fan 330 may be coupled to the first center panel 414 adjacent the front side 100 of the wire feeder 40. The circulation fan 330 is configured to suck circulating air from the second internal region and move the circulating air past the motor 312 and the gearbox 314 of the wire feeder 310 into the first internal region. The circulating air from the second interior region may be cooler in temperature than the ambient air around the motor 312 and gearbox 314 of the wire feeder 310 because the motor 312 and gearbox 314 of the wire feeder 310 may generate heat as they supply welding wire to welding torch 50 through the wire feed mechanism 310. As circulating air passes by motor 312 and gearbox 314, it cools motor 312 and gearbox 314 of wire feeder 310 by convection. Thus, as the circulating air passes by the motor 312 and gearbox 314 of the wire feeder 310, the temperature of the circulating air can rise at least slightly by absorbing some of the heat generated by the motor 312 and gearbox 314. This heated circulating air can continue to move upward. from the motor 312 and the gearbox 314 of the wire feeder 310 to the inlet 420 in the upper side wall 412 of the inner housing 410, as shown by arrows in FIG. 7C. Before entering the intermediate space 430 through the inlet 420, a portion of the heated circulating air may pass through the opening 440 in the first center panel 414 and thus into the second interior region. The remaining amount of heated circulating air, as shown in FIG. 7C may pass through the inlet 420 into the intermediate space 430. Circulating air may pass through the intermediate space 430 past the upper busbar opening 424, the lower busbar opening 426, and exit the intermediate space 430 through an outlet opening 422 adjacent the front side 100 of the wire feeder 40. A portion of the circulating air passing through the intermediate space 430 may be discharged into the second inner region as the circulating air passes through the upper busbar opening 424 and the lower busbar opening 426. The remaining amount of circulating air 430 exits the intermediate space 430 and enters the second inner region through the outlet 422.

[00110] When the cooling air passes through the intermediate space 430, the heat of the heated circulating air can be more easily dissipated through the outer housing 400 to the outside of the wire feeder 40. In addition, the closed circulating air loop described above allows the circulation fan 330 to pump circulating air inside the housing 120 of the wire feeder 40 without drawing air from outside the wire feeder 40 . This closed loop of circulating air eliminates the need for inlets and outlets in the body 120 of the wire feeder 40 to provide air flow into and out of the body 120 of the wire feeder 40 . This serves to prevent contaminated air that is outside the wire feeder 40 and is often present in areas where wire feeders are used from being used to cool the components of the wire feeder 40 . By eliminating the use of contaminated air to cool the components of the wire feeder 40, contamination of the internal cavity 300 of the wire feeder 40 and the components of the wire feeder 40 is also minimized, thereby increasing the life of the wire feeder 40. Eliminating the air circulation inlet and outlet holes located on the body 120 of the wire feeder 40 further serves to prevent water from entering the interior 300 of the wire feeder 40 and damaging the components of the wire feeder 40 . In addition, by pumping circulating air through the intermediate space 430, which contains the lower and upper busbars 342, 344, the circulating air passes around the lower and upper busbars 342, 344 and cools them through convection.

[00111] FIG. 8A, 8B, 8C, 8D, 8E and 8F illustrate strain relief device 140. As explained previously, the stress relief device 140 is located on the rear side 102 of the wire feeder 40. The strain relief device 140 extends outside the rear side 102 adjacent the bottom side 106 and the second side 110 of the wire feeder 40. The strain relief device 140 may be configured to reduce stresses occurring on the connecting cable 60, which, as illustrated in FIG. 8F may be a single cable that internally contains a welding power cable 600, a communication signal cable 610, a shielding gas cable 620, a cooling water supply cable 630, and a cooling water return cable 640.

[00112] The strain relief device 140 includes a housing adapter 500, a lock nut 520, a first internal cable clamp 540, and a second internal cable clamp 570. The housing adapter 500 is configured to be attached or secured to the rear side 102 of the housing 120 of the wire feeder 40 using a set of fasteners. As best illustrated in FIG. 8B, 8C, 8D, and 8E, the housing adapter 500 is substantially rectangular with an outer side 502 and an inner side 504. When coupled to the rear side 102 of the housing 120 of the wire feeder 40, the inner side 504 is positioned against the surface of the rear side 102 of the housing 120 of the wire feeder 40. wire. The housing adapter 500 includes a central opening 506 that extends through the housing adapter 500 from the outer side 502 to the inner side 504. On the outer side 502 of the housing adapter 500, a series of channels 508 are located around the central opening 506. In the illustrated embodiment, four channels 508 are located on equally spaced around the center hole 506. In other embodiments, any number of channels may be located around the center hole 506.

[00113] As best illustrated in FIG. 8D, the central hole 506 includes an inner surface 510. Located on the inner surface 510 of the central hole 506 is a series of projections or guides 512 that serve as alignment teeth. A series of projections 512 are equally spaced on the inner surface 510 of the central hole 506 such that each pair of adjacent projections defines a slot or gap 514. Because the series of projections 512 are equidistant from each other, each of the slots 514 is the same size (i.e. width).

[00114] As shown in FIG. 8A, 8B, 8C, 8D, 8E, and 8F, the lock nut 520 is substantially cylindrical and includes a first end 522, an opposing second end 524, and a side wall 526 that extends from the first end 522 to the second end 524. In some embodiments, a lock nut the nut 520 may be conical, where the first end 522 has a larger diameter than the second end 524. A first hole 528 is located at the first end 522 of the lock nut 520, and a second hole 529 is located at the second end 524 of the lock nut 520. The side wall 526 may define a channel 530 that extends from the first hole 528 to the second hole 529. As illustrated, the first hole 528 may have a larger diameter than the second hole 529. The lock nut 520 further includes a flange 532 extending from the side wall 526 adjacent the first end 522 of the lock nut. nuts 520. A set of tabs 534 is located on the side of the flange 532 that faces the first end 522 of the lock nut 520. In the illustrated embodiment, the flange 532 includes four tabs 534 that are evenly spaced around the flange 532 and thus around the first hole 528. The four tabs 534 may be sized, shaped, and spaced to fit into channels 508 located on the exterior 502 of the housing adapter 500.

[00115] As explained previously, strain relief device 140 further includes a first internal cable clamp 540 and a second internal cable clamp 570. The first internal cable clamp 540 may be semi-cylindrical in shape with a first end 542 and an opposing second end 544. The first cylindrical cable clamp 540 may also include an outer side 546, which may be substantially rounded, and an opposing inner side 548, which may be essentially flat. As further illustrated in FIG. 8D and 8E, the first internal cable clamp 540 may include a first portion 550 and a second portion 552, wherein the first portion 550 has a larger diameter than the second portion 552. The first portion 550 may be located adjacent the first end 542 of the first internal cable clamp 540. while the second portion 552 may be located adjacent the second end 544 of the first internal cable clamp 540. A series of projections 560 are located on the surface of the outer side 546 of the first internal cable clamp 540. In addition, these projections 560 are located on the surface of the outer side 546 of the first internal cable clamp 540 adjacent the first end 542 of the first internal cable clamp 540. Ribs 554 may be located on the surface of the second portion 552 on the outer side 546. The outer side 546 of the first internal cable clamp 540 may also include a central channel 562 that extends through the first and second portions 550, 552 between the first end 542 and the second end 544. How further illustrated, the inner side 548 includes two channels 564, 566 that are located on the inner side 548 and extend from the first end 542 to the second end 544 of the first inner cable clamp 540. In some embodiments, the first channel 564 of the inner side 548 may be wider and deeper than the second channel 566 of the inner side 548.

[00116] As best illustrated in FIG. 8D and 8E, the second internal cable clamp 570 is substantially similar to the first internal cable clamp in that the second internal cable clamp 570 may be a mirror image of the first internal cable clamp 540. Like the first inner cable clamp 540, the second inner cable clamp 570 may be semi-cylindrical in shape with a first end 572 and an opposing second end 574. The second cylindrical cable clamp 570 may also include an outer side 576, which may be substantially rounded, and an opposite inner side 578, which may be substantially flat. As illustrated, the first inner cable clamp 540 and the second inner cable clamp 570 are configured to abut each other, with the inner side 548 of the first inner cable clamp 540 and the inner side 578 of the second inner cable clamp 570 abutting each other. When the inner sides 548, 578 abut each other, the outer side 546 of the first inner cable clamp 540 and the outer side 576 of the second inner cable clamp 570 together form a generally cylindrical structure.

[00117] As further illustrated in FIG. 8D and 8E, the second internal cable clamp 570 may include a first portion 580 and a second portion 582, like the first internal cable clamp 540, where the first portion 580 has a larger diameter than the second portion 582. The first portion 580 may be located adjacent the first end 572 of the second inner cable clamp 570, while the second portion 582 may be located adjacent the second end 574 of the second inner cable clamp 570. Ribs 584 may be located on the surface of the second portion 582 on the outer side 546. When the first and second inner clamps 540, 570 abut each other, the first portions 550, 580 are aligned with each other, the second portions 552, 582 are aligned with each other, and the ribs 554, 584 are combined with each other.

[00118] As with the first internal cable clamp 540, a series of projections 590 are located on the surface of the outer side 576 of the second internal cable clamp 570 (see FIG. 8C). These projections 590 are located on the surface of the outer side 576 of the second inner cable clamp 570 adjacent the first end 572 of the second inner cable clamp 570. The protrusions 590 may be the same size and shape as the protrusions 560 of the first internal cable clamp 540. The outer side 576 of the second internal cable clamp 570 may also include a central channel 592 that extends through the first and second portions 580, 582 between the first end 572 and the second end 574.

[00119] As further illustrated, the inner side 578 of the second inner cable clamp 570, as in the first inner cable clamp 540, includes two channels 594, 596 that are located on the inner side 578 and extend from the first end 572 to the second end 574 of the second internal cable clamp 570. In some embodiments, the first channel 594 of the inner side 578 may be wider and deeper than the second channel 596 of the inner side 578. The first channel 594 of the second internal cable clamp 570 may have the same width and shape as the first channel 564 of the first internal clamp 540 cable, while the second channel 596 of the second internal cable clamp 570 may have the same width and shape as the second channel 566 of the first internal cable clamp 540. In addition, when the first and second internal clamps 540, 570 abut each other, the first channel 594 of the second internal cable clamp 570 can be aligned with the first channel 564 of the first internal cable clamp 540 such that the first channels 564, 594 together form first pipeline 598(1). In addition, the second channel 596 of the second internal cable clamp 570 may also be aligned with the second channel 566 of the first internal cable clamp 540 such that the second channels 566, 596 together form a second conduit 598(2).

[00120] As shown in FIG. 8F, the first and second internal terminals 540, 570 are configured to connect to the connecting cable 60 of the power supply 20. Before connecting the connecting cable 60 to the first and second internal terminals 540, 570, the end of the connecting cable 60 may be inserted through the lock nut 520 so that the end of the connecting cable 60 passes through the second hole 529, the conduit 530 and the first hole 528. After the lock nut 520 is pushed onto the end of the connecting cable 60, the connecting cable 60 can be connected to the first and second internal cable clamps 540, 570. As illustrated in FIG. 8F, the connecting cable 60 may include a single sheath that contains inside a welding power cable 600, a communication signal cable 610, a shielding gas cable 620, a cooling water supply cable 630, and a cooling water return cable 640.

[00121] Before the first and second clamps 540, 570 are mated to each other, a portion of the welding power cable 600 that is spaced from the connector of the welding power cable 600 may be inserted into the first channel 594 of the second internal cable clamp 570. Likewise, a portion of the communication signal cable 610 that is spaced from the connector of the communication signal cable 610 may be inserted into the second channel 596 of the second internal cable clamp 570. When the first internal cable clamp 540 abuts the second internal cable clamp 570, the welding power cable 600 is captured within the first conduit 598(1) formed by the first channels 564, 594 of the first and second internal cable clamps 540, 570. Likewise, the communications signal cable 610 may be captured within a second conduit 598(2) formed by the second channels 566, 596 of the first and second internal cable clamps 540, 570. Once the first and second inner clips 540, 570 abut each other, fasteners 650 can be used to secure the first and second inner clips 540, 570 to each other. In addition, a portion of the shielding gas cable 620 may be housed within the center passage 592 of the second inner cable clamp 570, while portions of the cooling water supply and return cables 630, 640 may be placed within the center passage 562 of the first inner cable clamp 540. or vice versa. After the cables 600, 610, 620, 630, 640 are properly installed in their respective positions on the first and second inner clamps 540, 570, the connector cable sheath 60 can be placed over the second portions 552, 582 of the first and second inner clamps 540, 570. In some embodiments, the sheath may be attached to the second portions 552, 582 of the first and second inner clamps 540, 570 using cable ties or clamps. The ribs 554, 584 may serve to secure or hold the cable ties and interconnect cable sheath 60 to the second portions 552, 582 by means of the cable ties located between the ribs 554, 584.

[00122] After the interconnect cable 60 and associated internal cables 600, 610, 620, 630, 640 are connected to the first and second internal terminals 540, 570, the ends of the internal cables 600, 610, 620, 630, 640 may be inserted through the hole 506 of the housing adapter 500 mounted on the rear side 102 of the wire feeder 40. The ends of the internal cables 600, 610, 620, 630, 640 can then be connected to their respective connectors 352, 354(1), 354(2), 356, 358 of the connection panel 350 located in the internal cavity 300 of the wire feeder 40. As best illustrated in FIG. 8C, the first and second internal clips 540, 570 can then be inserted into the hole 506 of the housing adapter 500. When the first and second inner clips 540, 570 are inserted into the hole 506, the projections 560, 590 of the first and second inner clips 540, 570, respectively, can be inserted into the slots 514 of the housing adapter 500 that are located between the projections 512. The projections 512 of the housing adapter 500 may be shaped to guide the projections 560, 590 of the first and second internal clamps 540, 570 into the slot 514. The engagement of the projections 560, 590 of the first and second internal clamps 540, 570 with the slots 514 and projections 512 of the housing adapter 500 prevents rotation of the first and second internal clamps 540, 570, and thus internal cables 600, 610, 620, 630, 640 relative to the housing adapter 500 and the wire feeder 40 itself.

[00123] Once the first and second inner clips 540, 570 are inserted into the hole 506 of the body adapter 500, a lock nut may be removably coupled to the outside 502 of the body adapter 500 to secure the first and second inner clips 540, 570 to the adapter 500 of the housing and within the conduit 530 of the locking nut 520. As previously explained, the projections 534 of the locking nut 520 are configured to fit into the channels 508 of the housing adapter 500. The first end 522 and flange 532 of the lock nut 520 may be abutted against the outer side 502 of the body adapter 500, with the projections 534 of the lock nut 520 being offset or misaligned with the channels 508 of the body adapter 500. The lock nut 520 can then be rotated in a first direction to slide the projections 534 of the lock nut 520 into the channels 508 of the body adapter 500, which secures the lock nut 520 to the body adapter 500. In some embodiments, the channels 508 may include a protrusion configured to receive a recess in the protrusions 534 when the protrusions 534 of the lock nut 520 are pushed far enough into the channels 508. This allows the lock nut 520 to be further secured to the body adapter 500 and also provides tactile feedback communication indicating to the operator of the welding device 40 when the lock nut 520 is successfully attached to the housing adapter 500. When the lock nut 520 is attached to the body adapter 500, the first and second internal clamps 540, 570 are captured between the body adapter 500 and the second end 524 of the lock nut 520 because the second hole 529 has a smaller diameter than the combination of the first and second second ends 544, 574 internal clamps 540, 570.

[00124] Since the stress relief device 140, as described and illustrated in FIG. 8A, 8B, 8C, 8D, 8E and 8F, clamps at least some of the internal cables 600, 610, 620, 630, 640 of the interconnect cable 60 adjacent to the ends or connectors of the internal cables 600, 610, 620, 630, 640, device 140 Strain relief keeps internal cable connectors 600, 610, 620, 630, 640 apart from each other. Thus, by clamping at least some of the internal cables 600, 610, 620, 630, 640 and the sheath of the connecting cable 60 to the strain relief device 140, and then connecting the strain relief device 140 to the rear side 102 of the housing 120 of the wire feeder 40 stress is reduced when connecting internal cables 600, 610, 620, 630, 640 to their respective connectors 352, 354(1), 354(2), 356, 358. The strain relief device 140 described above prevents movement of the interconnect cable 60 (t i.e., resulting from the movement of the connecting cable 60 itself, the movement of the wire feeder 40, the movement of the power source 20, etc.), and accordingly the tension and deformation of the connection of the internal cables 600, 610, 620, 630, 640 with their respective connectors 352, 354(1), 354(2), 356, 358. Thus, strain relief 140 prevents unintentional damage to connectors 352, 354(1), 354(2), 356, 358 and/or disconnection of internal cables 600. 610, 620, 630, 640 from their respective connectors 352, 354(1), 354(2), 356, 358 when the connecting cable 60 moves relative to the wire feeder 40.

[00125] FIG. 9A, 9B and 9C show one embodiment of the control panel 130 of the wire feeder 40. As explained previously, the control panel 130 may be mounted on the front side 100 of the housing 120 of the wire feeder 40. As best illustrated by the exploded view of FIG. 9C, control panel 130 consists of an outer base member 700, a rigid printed circuit board (PCB) 720, a pair of encoders 730, a set of adjustment knobs 740, and a series of buttons 750. As best illustrated in FIG. 9A and 9B, base member 700 is generally rectangular with an outer side 702 and an opposing inner side 704. Base member 700 can be made from a variety of materials, including, but not limited to, thermoplastic polymers. As illustrated in FIG. 9B, the base member 700 includes a plurality of side walls 706 that extend from the inner side 704 and define a cavity 708.

[00126] As shown in FIG. 9C, a plurality of holes 710, 712, 714 are arranged along the base member 700 such that they extend through the base member 700 between the outer side 702 and the inner side 704. The first set of holes are display holes 710 that can be oriented at specific positions on base element 700 for displaying numerical values, error codes, warnings, etc., as will be described in more detail below. The adjustment knob holes 712 are located on the base member 700 and are configured to receive a portion of the encoders 730 that are coupled to the inner side 704 of the base member 700 such that the shaft portion 732 of the encoders 730 extends through the adjustment knob holes 712 and exits the outer side 702 base element 700. The adjustment knobs 740 may be coupled to a shaft portion 732 of the encoders 730 on the outer side 702 of the base member 700. The button holes 714 may be positioned horizontally across the base member 700 and located in an elongated recess or recess 716 on the surface of the outer side 702 of the base member 700. As further illustrated, base member 700 also includes a set of mounting holes 718 located adjacent the top corners of base member 700. As described in more detail below, these mounting holes 718 may be used to secure the control panel 130 to the housing 120 of the wire feeder 40.

[00127] As best illustrated in FIG. 9C, rigid PCB 720 has a first side 722 and an opposing second side 724. Like base member 700, rigid PCB 720 is substantially rectangular and can be sized to match the size of cavity 708 of base member 700. When placed within the cavity 708, the first side 722 of the rigid PCB 720 is positioned against the inner side 704 of the base member 700. The rigid PCB 720 may be attached to the inside 704 of the base member 700 using a set of fasteners 760 (eg, screws), which are shown in FIG. 9B. As shown in FIG. 9C, the rigid PCB 720 further includes a pair of centralized holes 726 and a row of pushbutton switches 728. The centralized holes 726 are positioned on the rigid PCB 720 such that when the rigid PCB is attached to the inside 704 of the base member 700, the centralized holes 726 align with the holes 712 for the adjustment knobs of element 700 of the base. The centralized holes 726 are sized to at least partially receive the base 734 of the encoders 730 when the rigid PCB 720 and the encoders 730 are attached to the inside 704 of the base member 700. Fig. 9C further illustrates that a row of pushbutton switches 728 of the rigid PCB 720 are located on the first side 722 of the rigid PCB 720 in a horizontal arrangement. The pushbutton switches 728 are sized to fit inside the button holes 714 of the base member 700 and to at least partially extend from the button holes 714 of the base member 700 . Although not illustrated, the rigid PCB 720 may be further provided with light emitting diodes (LEDs) located on the first side 722 of the rigid PCB 720. These LEDs may be aligned with the display holes 710 when the rigid PCB 720 is secured within the cavity 708 of the inner side 704 of the base member 700 . Thus, these LEDs may be configured to shine through display openings 710 to display numerical values, error codes, warnings, etc. For example, display holes 710 and LEDs can be arranged such that a predetermined number of LEDs can light up relative to the display holes 710 to display numerical values of welding operating parameters.

[00128] As illustrated in FIG. 9B, the encoders 730 are mounted on the inside 704 of the base member 700 within the cavity 708. More specifically, the base 734 of each of the encoders 730 connects to the inside 704 of the base member 700 adjacent the hole 712, where the rotation shaft 732 of the encoder 730 passes through the hole 712 perpendicular to surface of the outer side 702 of the base element 700. The rotary shaft 732 is configured to receive and connect to the adjustment knob 740. The encoders 730 further include a connector 736 that extends rearward from the base 734. The connectors 736 of the encoders 730 may be coupled to the rigid PCB 720. The encoders 730 may be configured to be translatable the rotational position of the adjustment knobs 740 and the rotation shafts 732 into a control command or input for the wire feeder 40.

[00129] As illustrated in FIG. 9C, a set of buttons 750 may be coupled to the outer side 702 of the base member 700. More specifically, the set of buttons 750 is a series of raised actuators 752 located on a rectangular base 754. The rectangular base 754 may be sized to fit a recess 716 on the outside 702 of the base member 700, while the actuators 752 are aligned with the button holes 714 and ultimately with the switches 728 of the rigid PCB 720 located inside the button holes 714. The set of buttons 750 may be made of an elastic and flexible material (e.g., rubber) such that pressing one of the actuators 752 actuates its corresponding switch 728 of the rigid PCB 720.

[00130] As illustrated in FIG. 3A and 9D, the control panel 130 may be mounted on the front side 100 of the housing 120 of the wire feeder 40 in various orientations. In FIG. 3A, the wire feeder 40 is oriented in a vertical position, where the bottom side 106 of the wire feeder 40 is located on the support surface. In this orientation of the wire feeder, the control panel 130 is installed in the first configuration C, where the mounting holes 718 are located closer to the top side 104 than to the bottom side 106 of the wire feeder 40. However, as previously explained, the wire feeder 40 may be used in a horizontal orientation, where the first side 108 or the second side 110 of the wire feeder 40 serves as the bottom of the wire feeder 40. In this orientation, the control panel 130 can be removed from the wire feeder 40, rotated 90 degrees either clockwise (with the first side 108 serving as the bottom of the wire feeder 40) or counterclockwise (with the second side 110 serving as the bottom of the device 40 wire feeder) and then reinstalled in this second configuration D. In the second configuration D, both mounting holes 718 are located adjacent to the second side 110 (when the first side 108 serves as the bottom of the wire feeder 40), or to the first side 108 (when the second side 110 serves as the bottom of the wire feeder 40).

[00131] Although not illustrated in FIG. 9A, 9B, and 9C, some embodiments of the control panel 130 may include a substantially flat and translucent panel positioned against the outer side 702 of the base member 700.

[00132] In FIG. 10A, 10B and 10C show the wire feed mechanism 310 of the wire feeder 40. The wire feeder 310 includes a front side 800, a rear side 802 opposite the front side 800, an input side 804 located between the front side 800 and the rear side 802, and an output side 806 opposite the input side 804. The wire feeder 310 also includes including a top side 808 that extends between front and rear sides 800, 802, inlet and outlet sides 804, 806, and a bottom side 809 opposite the top side 808. The wire feeder 310 consists of a first housing portion 810, a second housing portion 860 , drive motor 312 and gearbox 314 (see Fig. 7C). The first housing portion 810 may be located on the front side 800 of the wire feeder 310, while the second housing portion 860 may be located on the rear side 802 of the wire feeder 310. In addition, the drive motor 312 may be coupled to a gearbox 314, which may be coupled to a second housing portion 860 on the rear side 802 of the wire feeder 310. As explained previously, the wire feed mechanism 310 is configured to receive welding wire from the spool 320 and advance the welding wire along the torch cable 62 to the welding torch 50 to perform a welding operation.

[00133] As best illustrated in FIG. 10C, the first housing portion 810 includes an outer side 811 that mainly forms a front side 800 of the wire feeder 310, an inner side 812 that connects to the second housing portion 860, a first side 813 that forms a section of the input side 804 of the wire feeder 310 wire, and a second side 814 that forms a section of the output side 806 of the wire feeder 310.

[00134] Located on the outer side 811 of the first housing portion 810 are four holes 816(1), 816(2), 816(3), 816(4) for drive wheels. A first pair of drive wheel holes 816(1), 816(2) is located on the first housing portion 810 adjacent the first side 813, and a second pair of drive wheel holes 816(3), 816(4) is located on the first housing portion 810 adjacent with the second side 814. The first pair of drive wheel holes 816(1), 816(2) may be oriented relative to each other such that the second drive wheel hole 816(2) is positioned vertically above the first drive wheel hole 816(1). wheels. The first and second drive wheel openings 816(1), 816(2) may be in fluid communication with each other and with the inlet 820 (see FIG. 10B). Likewise, the second pair of drive wheel holes 816(3), 816(4) may be oriented relative to each other such that the fourth drive wheel hole 816(4) is positioned vertically above the third drive wheel hole 816(3). The third and fourth drive wheel openings 816(3), 816(4) may also be in fluid communication with each other and with the outlet opening 822. As illustrated in FIG. 10A, 10B and 10C, an inlet 820 is located on the first housing portion 810 on the first side 813, while an outlet 822 is located on the first housing portion 810 on the second side 814. Also located on the second side 814 of the first housing portion 810 are mounting holes. 828.

[00135] Within the drive wheel holes 816(1), 816(2), 816(3), 816(4) are drive wheels 818(1), 818(2), 818(3), 818(4) ( see Fig. 10A). The first pair of drive wheels 818(1), 818(2) may be located within the first pair of drive wheel openings 816(1), 816(2), while the second pair of drive wheels 818(3), 818(4) may be located inside the second pair of drive wheel holes 816(3), 816(4). Drive wheels 818(1), 818(2), 818(3), 818(4) may be driven by drive motor 312, gearbox 314, and a number of gears operatively coupled to drive wheels 818(1), 818(2), 818(3), 818(4), and a gearbox 314. The first drive wheel 818(1) of the first pair of drive wheels may be configured to rotate about a first direction, while the second drive wheel 818(2) of the first pair of drive wheels may be configured to rotate about a second direction opposite to the first direction. More specifically, the first drive wheel 818(1) may be rotated in a clockwise direction, while the second drive wheel 818(2) may be configured to rotate in a counterclockwise direction. Likewise, the third and fourth drive wheels 818(3), 818(4) of the second pair of drive wheels are configured to rotate in opposite directions. The third drive wheel 818(3) may be rotated in a clockwise direction, while the fourth drive wheel 818(4) may be configured to rotate in a counterclockwise direction. This counter rotation of the first pair of drive wheels 818(1), 818(2) acts on the welding wire located between the first pair of drive wheels 818(1), 818(2) so as to advance the welding wire towards the second pair of drive wheels 818( 3), 818(4). Likewise, the counter-rotation of the second pair of drive wheels 818(3), 818(4) acts on the welding wire located between the second pair of drive wheels 818(3), 818(4) so as to advance the welding wire from the exit hole 822.

[00136] The first housing portion 810 also includes a pair of actuator openings 824(1), 824(2). The first actuator hole 824(1) is located between the first side 813 and the first pair of drive wheel holes 816(1), 816(2), where the first actuator hole 824(1) extends through the first housing portion 810 between the outer side 811 and the inner side 812. The first actuator opening 824(1) may be in fluid communication with the inlet opening 820. The second actuator opening 824(2) is located between the second side 814 and the second pair of openings 816(3), 816 (4) for drive wheels, and, like the first actuator hole 824(1), extends through the first housing portion 810 between the outer side 811 and the inner side 812. The second actuator hole 824(2) may be fluidly coupled environment with an outlet 822. A central opening 850 is located on the outer side 811 of the first housing portion 810 between a first pair of drive wheel openings 816(1), 816(2) and a second pair of drive wheel openings 816(3), 816(4). . The central opening 850 includes a first passage 852 that extends from the central opening 850 to a first side 813 and a first pair of drive wheel openings 816(1), 816(2), and a second passage 854 that extends from the central opening 850 to the second side 814 and to the second pair of holes 816(3), 816(4) for the drive wheels. Thus, the central opening 850 is in fluid communication with the first and second drive wheel openings 816(1), 816(2) through the first passage 852, and is in fluid communication with the third and fourth openings 816(3), 816(4). ) for the drive wheels through the second pass 854.

[00137] Also located in the first housing portion 810 is a pair of tensioner slots 826(1), 826(2). The first tensioner slot 826(1) extends onto the outer side 811 of the first housing portion 810 adjacent the first side 813 and vertically above the first actuator opening 824(1). A second tensioner slot 826(2) extends onto the outer side 811 of the first housing portion 810 adjacent to the second side 814 and vertically above the second actuator opening 824(2).

[00138] The upper side of the first housing portion 810 may be formed from a pair of clamping arms 830(1), 830(2) that are rotatably coupled to the same axis 838. The axis 838 may be positioned equidistant from the first side 813 and the second side 814 of the first housing part 810. The first ends 832(1), 832(2) may be coupled to the axle 838. The second end 834(1) of the first clamp arm 830(1) may be positioned adjacent the first side 813 of the first housing portion 810 while the second end 834(2) of the second clamping lever 830(2) may be located adjacent to the second side 814 of the first housing portion 810. As further illustrated, the second ends 834(1), 834(2) of the clamp arms 830(1), 830(2), respectively, include slits 836(1), 836(2), respectively. The slots 836(1), 836(2) of the clamp arms 830(1), 830(2) may be substantially aligned with the tensioner slots 826(1), 826(2).

[00139] The wire feeder 310 further includes a pair of tensioners 840(1), 840(2) located on the first housing portion 810. Both tensioners 840(1), 840(2) include an elongate member 842, a force transmission portion 844, and an adjustment knob 846. The first tensioner 840(1) is rotatably coupled to the first tensioner slot 826(1) so that that the elongated member 842(1) is at least partially located within the first tension device slot 826(1), while the second tension device 840(2) is rotatably coupled to the second tension device slot 826(2) so that the elongated element 842(2) is at least partially located inside the second tension device slot 826(2). When the first tensioner 840(1) is in the closed position, as illustrated, the elongate member 842(1) of the first tensioner 840(1) is at least partially located within the slot 836(1) of the first clamp lever 830(1), while while the force transmitting member 844(1) abuts the second end 834(1) of the first clamping arm 830(1). Likewise, when the second tensioner 840(2) is in the closed position, the elongate member 842(2) of the second tensioner 840(2) is at least partially located within the slot 836(2) of the second clamp lever 830(2), while while the force transmitting member 844(2) abuts the second end 834(2) of the second clamping arm 830(2). The tensioners 840(1), 840(2) can be rotated around the ends of the elongated members 842(1), 842(2) into open positions (not shown) where the elongated members 842(1), 842(2) are no longer internally positioned slots 836(1), 836(2) clamping levers 830(1), 830(2), respectively.

[00140] The adjustment knobs 844(1), 844(2) of the tensioners 840(1), 840(2) can be rotated to cause the force transmission element 842(1), 842(2) to increase or decrease the force applied to the second ends 834(1), 834(2) clamping levers 830(1), 830(2), respectively. Increasing the force applied to the second end 834(1) of the first clamping arm 830(1) rotates the second drive wheel 818(2) closer to the first drive wheel 818(1), which increases the clamping force applied by the two drive wheels 818(1). ), 818(2) to the welding wire located between these two drive wheels 818(1), 818(2). Likewise, increasing the force applied to the second end 834(2) of the second clamping arm 830(2) rotates the fourth drive wheel 818(4) closer to the third drive wheel 818(3), which increases the clamping force applied by the two drive wheels. 818(3), 818(4) to the welding wire located between these two drive wheels 818(3), 818(4). This positioning of the second drive wheel 818(2) relative to the first drive wheel 818(1) and the fourth drive wheel 818(4) relative to the third drive wheel 818(3) allows the user to adjust the clearance between the drive wheels 818(1), 818(2), 818(3), 818(4) based on welding wire gauge and wear level of drive wheels 818(1), 818(2), 818(3) and 818(4).

[00141] As best illustrated in FIG. 10B, the second housing portion 860 includes an outer side 861 that primarily forms a rear side 802 of the wire feeder 310, an inner side 862 that connects to the inner side 812 of the first housing portion 810, and a first side 863 that together form an input a side 804 of the wire feeder 310 with a first side 813 of the first housing portion 810, and a second side 864, which together form the output side 806 of the wire feeder 310 with a second side 814 of the first housing portion 810.

[00142] The inner side 862 of the second housing portion 860 includes an actuator input channel 870 and an actuator output channel 880. An actuator input port 870 may be located on an interior side 862 of a second housing portion 860 adjacent a first side 863 of a second housing portion 860, while an actuator output passage 880 may be located on an interior side 862 of a second housing portion 860 adjacent a second side. 864 second part 860 of the body. In addition, when the first and second housing portions 810, 860 are connected to each other, the actuator inlet channel 870 may be aligned with the first actuator hole 824(1), while the actuator outlet channel 880 may be aligned with the second hole 824(2) for the actuator. The actuator inlet channel 870 may include a center passage 872 and a pair of slots 874 located on the top and bottom sides of the actuator inlet channel 870. Similar to the actuator input channel 870, the actuator output channel 880 may include a center passage 882 and a pair of slots 884 located on the upper and lower sides of the actuator output channel 880. These channels 870, 880, together with the first and second actuator openings 824(1), 824(2), are configured to receive sliding actuators 900.

[00143] As best illustrated in FIG. 10A, 10B and 11, the sliding actuators 900 include a first end 910 and an opposing second end 920. The sliding actuators 900 can be slidably supported within the input and output actuator channels 870, 880 and are slidable between an unengaged position and an engaged position. The sliding actuators 900 may slide along the channels 870, 880, but the second ends 920 of the sliding actuators 900 remain located in the channels 870, 880 regardless of the position in which the sliding actuators 900 are located.

[00144] As best illustrated in FIG. 11, the second ends 920 of the push-button actuators 900 include upper and lower retention hooks 922 that are configured to engage the upper and lower slots 874, 884 of the actuator input and output channels 870, 880, respectively. The interaction of the retaining hooks 922 with the upper and lower slots 874, 884 of the actuator inlet and outlet channels 870, 880, respectively, retains the sliding actuators 900 within the actuator inlet and outlet channels 870, 880, allowing them to slide along the inlet and outlet channels 870. 880 actuator. At the second end 920 of the sliding actuators 900, guide protrusions 924 are located between the retaining hooks 922. The guide protrusions 924 are configured to receive an elastic element 926 (e.g., a spring) that may be located within the actuator inlet channel 870 and the actuator outlet channel 880. The resilient member 926 may be configured to bias the sliding actuators 900 to a disengaged state when the first end 910 of the sliding actuators 900 protrudes outward from the first and second actuator openings 824(1), 824(2). When the sliding actuators 900 are depressed (that is, when force is applied to the first ends 910 of the sliding actuators 900 to cause the first ends 910 to slide into the first housing portion 810) into their engaged state, the sliding actuators 900 slide along the inlet and outlet channels 870. 880 of the actuator to the rear side 802 of the wire feeder 310 to compress the elastic element 926. When the force pressing on the sliding actuators 900 is no longer applied to the first ends 910, the elastic elements 926 return the sliding actuators 900 to their unactuated state.

[00145] As best illustrated in FIG. 11, each push-button actuator 900 includes an opening 930 located between the first end 910 and the second end 920. The opening 930 may be an elongated opening having a first side 932 wider than the second side 934, wherein the first side 932 of the opening 930 may be located closer to the first end 910 of the button actuator 900 than the second side 934 of the hole 930. This oblong shape of the hole 930 allows the hole 930 of the button actuator 900 to engage the input or output guide 1000, 1100 when the button actuator 900 is in a disengaged state, being displaced by the elastic element 926.

[00146] As illustrated in FIG. 11, the entry guide 1000 is substantially cylindrical with a first end 1010 and a second end 1020. The entry guide 1000 further includes a recessed segment 1030 located on the surface of the entry guide 1000 between the first end 1010 and the second end 1020. The second end 1020 may further include includes a conical segment 1022 configured to be positioned adjacent the first and second drive wheels 818(1), 818(2) when the inlet guide 1000 is positioned within the inlet opening 820. The inlet guide 1000 also includes a conduit 1040 that extends through input guide 1000 from the first end 1010 to the second end 1020. The conduit 1040 of the input guide 1000 may be configured and sized to receive welding wire.

[00147] FIG. 11 also illustrates that the exit guide 1100 is substantially cylindrical with a first end 1110 and a second end 1120. The exit guide 1100 may be longer than the entry guide 1000. Like the entry guide 1000, the exit guide 1100 includes a recessed segment 1130. located on the surface of the exit rail 1100 between the first end 1110 and the second end 1120. While the recessed segment 1030 of the inlet rail 1000 may be located on the input rail 1000 so that it is equidistant from the first and second ends 1010, 1020, the recessed segment 1130 the exit guide 1100 is located closer to the second end 1120 than to the first end 1110. In addition, the second end 1120 may further include a conical segment 1122 configured to be located adjacent to the third and fourth drive wheels 818(3), 818(4). ) when the exit guide 1100 is located within the outlet opening 822. The exit guide 1100 also includes a conduit 1140 that extends through the exit guide 1100 from the first end 1110 to the second end 1120. The conduit 1140 of the exit guide 1100 may be configured and sized to accept welding wire.

[00148] As shown in FIG. 10A, 10B and 10C, the input guide 1000 may be inserted through the input opening 820 of the first housing portion 810 such that the second end 1020 is located adjacent the first and second drive wheels 818(1), 818(2). When the inlet guide 1000 is positioned within the inlet 820, the inlet guide 1000 is captured and secured within the inlet 820 by the push-button actuator 900. More specifically, when the inlet guide 1000 is completely located within the inlet 820, the recessed segment 1030 of the inlet guide 1000 may be aligned with the first hole 824(1) of the actuator. The second side 934 of the hole 930 of the push-button actuator 900, located inside the first hole 824(1) of the actuator, engages with the recessed segment 1030 of the input guide 1000 when the push-button actuator 900 is in a disengaged state to lock the input guide 1000 within the input hole 820. To remove the entry guide 1000 from the entry opening 820, the welder may press the push-button actuator 900 to move the wider first side 932 of the push-button actuator 930 hole 930 toward the entry guide 1000 and also disengage the second side 934 of the push-button actuator 930 hole 930. with the recessed segment 1030 of the input guide 1000. The separation of the second side 934 of the hole 930 of the push-button actuator 900 and the recessed segment 1030 when the push-button actuator 900 is pressed allows the welder to pull the input guide 1000 from the input hole 820 without the use of a tool.

[00149] Similar to the input guide 1000, the output guide 1100 may be inserted through the outlet opening 822 of the first housing portion 810 such that the second end 1120 is located adjacent the third and fourth drive wheels 818(3), 818(4). When the exit guide 1100 is positioned within the exit opening 822, the exit guide 1100 is captured and secured within the exit opening 822 by the push-button actuator 900. More specifically, when the exit guide 1100 is completely located within the exit opening 822, the recessed segment 1130 of the exit guide 1100 may be aligned with the second hole 824(2) of the actuator. The second side 934 of the opening 930 of the push-button actuator 900, located inside the second opening 824(2) of the actuator, engages with the recessed segment 1130 of the output guide 1100 when the push-button actuator 900 is in the disengaged state to lock the output guide 1100 within the output opening 822. As best illustrated in FIG. 10A, since the output guide 1100 is longer than the input guide 1000, when the output guide 1100 is located inside the output hole 820, the output guide 820 protrudes significantly from the output side 806 of the wire feeder 310. To remove the exit guide 1100 from the exit hole 820, the welder may press the push-button actuator 900 to move the wider first side 932 of the push-button actuator 930 hole 930 toward the exit guide 1100 and also disengage the second side 934 of the push-button actuator 930 hole 930. with the recessed segment 1130 of the exit guide 1100. Disconnecting the second side 934 of the hole 930 of the push-button actuator 900 and the recessed segment 1130 by pressing the push-button actuator 900 allows the welder to pull the exit guide 1100 from the exit hole 822 without the use of a tool.

[00150] As illustrated in FIG. 12A and 12B, the intermediate wire guide 1200 includes a cylindrical member 1210 and an actuator clamp 1230. The cylindrical member 1210 includes a first end 1212 and an opposing second end 1214. In the illustrated embodiment, the ends 1212, 1214 of the cylindrical member 1210 may taper to be positioned adjacent the drive wheels 818(1), 818(2), 818(3). , 818(4) when located inside the central opening 850 of the first housing portion 810 of the wire feed mechanism 310. An embodiment of the intermediate wire guide 1200 illustrated in FIG. 12A and 12B includes three segments 1216, 1217 and 1218. A first segment 1216 is located adjacent the first end 1212, a third segment 1218 is located adjacent the second end 1214, and a second segment 1217 is located between the first and third segments 1216, 1218. The second segment 1217 may be a recess located in the surface of cylindrical element 1210 that extends only partially around cylindrical element 1210 (that is, the recess does not extend completely 360 degrees around cylindrical element 1210).

[00151] The actuator clamp 1230 may include a center member 1240, an upper arm 1250, and a lower arm 1260. The center member 1240 includes a distal end 1242 and an opposing proximal end 1244. At the distal end 1242 of the central member 1240 are clamping members 1246 configured to engage the recess of the second segment 1217 to secure the actuator clamp 1230 to the cylindrical member 1210. An upper arm 1250 extends upward and forward from a proximal end 1244 of the center member 1240 to a distal end 1242 of the center member 1240. The upper arm 1250 may include an end 1252 and a protrusion 1254 located adjacent the end 1252 of the upper arm 1250. Likewise, a lower arm 1260 extends downwardly and forwardly from a proximal end 1244 of the center member 1240 to a distal end 1242 of the center member 1240. The lower arm 1260 may include an end 1262 and a protrusion 1264 located adjacent the end 1262 of the lower arm 1260. The upper and lower arms 1250, 1260 may have some degree of resiliency such that they can function as living hinges relative to the central member 1240.

[00152] As best illustrated in FIG. 12B, the intermediate wire guide 1200 can be removably coupled to the first housing portion 810 through the central opening 850. When the cylindrical member 1210 is connected to the fastening clip 1230, the second segment 1217 of the cylindrical member 1210 and the fastening clip 1230 can be inserted into the central opening 850, at while the first segment 1216 of the cylindrical element 1210 is simultaneously inserted into the first passage 852, and the second segment 1218 of the cylindrical element 1210 is inserted into the second passage 854. When inserted into the central opening 850, the projections 1254, 1264 of the fastening clip 1230 engage the side walls of the central opening 850, holding the fastening clip 1230 inside the central opening 850. Since the fastening clip 1230 is connected to the cylindrical element 1210, the engagement of the projections 1254, 1264 with the side walls of the central opening 850 also holds the cylindrical element 1210 inside the central opening 850, the first passage 852 and the second passage 854. When the intermediate wire guide 1200 is connected to the central opening 850 of the first body portion 810 of the wire feeder 310, the first end 1212 of the cylindrical member 1210 of the intermediate wire guide 1200 is positioned adjacent the first and second drive wheels 818(1), 818(2), in while the second end 1214 of the cylindrical member 1210 is located adjacent to the third and fourth drive wheels 818(3), 818(4).

[00153] In FIG. 12C and 12D show other embodiments of the intermediate wire guide 1200. As illustrated in FIG. 12C, the recess of the second segment 1217 of the cylindrical element 1210 extends completely around the surface of the cylindrical element 1210. This allows the cylindrical element 1210 to rotate relative to the fastening clamp 1230 when the cylindrical element 1210 is secured within the clamping elements 1246. As illustrated in FIG. 12D, the cylindrical member 1210 and the fastening clip 1230 are uniformly formed such that the intermediate wire guide 1200 is formed as one member.

[00154] In FIG. 13A, 13B, 13C, and 13D show an additional embodiment for holding the entry rail 1000 within the entry opening 820 and the exit guide 1100 within the exit opening 822, which is a latch 1300. While FIG. 13A, 13B, 13C and 13D illustrate only the input side 804 of the first housing portion 810 and the interaction of the latch 1300 with the input side 804 of the first housing portion 810, discussion of FIG. 13A, 13B, 13C and 13D also refer to the outlet side 806 of the first housing portion 810, the outlet opening 822, the second actuator opening 824(2), and the exit guide 1100. In the embodiment illustrated in FIG. 13A, 13B, 13C and 13D, the latch 1300 may be configured to retain the entry guide 1000 within the entry opening 820 in place of the push-button actuator 900. FIG. 13A and 13B illustrate the latch 1300 in a locked position relative to the first housing portion 810, while FIG. 13C and 13D illustrate the latch 1300 in an unlocked position relative to the first housing portion 810. As illustrated, the latch 1300 is pivotally coupled to the first actuator opening 824(1) of the first housing portion 810 and is rotatable or rotatable between the unlocked and locked positions.

[00155] The latch 1300 may have a body 1310 that includes a lever portion 1310, a hook portion 1330, and a hinge portion 1340. As further illustrated in FIG. 13B and 13D, the hook portion 1330 includes a locking member 1332 configured to engage or abut the protrusion 1350 of the first actuator opening 824(1) and the end 1334. As illustrated in FIG. 13A, 13B, 13C, 13D, in both the unlocked and locked positions, the lever portion 1310 of the latch 1310 extends outward from the first actuator opening 824(1) such that the lever portion 1310 can be engaged by a welder. When the latch 1300 is in the locked position (FIGS. 13A and 13B), the lever portion 1310 can be pulled downward and outward by the welder to rotate the latch 1300 about the hinge portion 1340 to the unlocked position (FIGS. 13C and 13D). As illustrated in FIG. 13D, the latch 1300 can be rotated from the first actuator hole 824(1) until the locking member 1332 on the hook portion 1330 comes into contact with the protrusion 1350 of the first actuator hole 824(1). When the latch 1300 is in the unlocked position (FIGS. 13C and 13D), the lever portion 1310 can be pushed upward toward the first housing portion 810 to rotate the latch 1310 about the hinge portion 1340 into the first actuator hole 824(1) until until the lever portion 1310 comes into contact with the protrusion 1350 of the first actuator hole 824(1).

[00156] As explained above with respect to FIG. 10A, 10B, and 10C, the first actuator opening 824(1) extends through the entry opening 820. When the latch 1300 is in the unlocked position, the entry guide 1000 may be inserted into the entry opening 820 of the first housing portion 810 such that the second end 1020 is located next to the first and second drive wheels 818(1), 818(2). In addition, when the inlet guide 1000 is completely located within the inlet hole 820, the recessed segment 1030 of the inlet guide 1000 can be aligned with the first actuator hole 824(1). When the entry guide 1000 is fully positioned within the entry opening 820, the latch 1300 can be rotated from an unlocked position to a locked position. This causes the end 1334 of the hook portion 1330 to slide along the entry guide 1000 until the entire hook portion 1330 engages the recessed segment 1030 of the entry guide 1000. The hook portion 1330 may be configured to deform slightly to allow the end 1334 of the hook portion 1330 to slide. along the entry guide 1000. When the hook portion 1330 engages with the recessed portion 1030 of the entry guide 1000, the entry guide 1000 is secured within the entry opening 820.

[00157] To remove the entry guide 1000 from the entry opening 820, the welder can rotate the latch 1300 from a locked position to an unlocked position, as previously explained. Rotation of the latch 1300 to the unlocked position causes the hook portion 1330 of the latch 1300 to disengage from the recessed segment 1030 of the entry rail 1000, and the end 1334 of the hook portion 1330 slides along the entry guide 1000. The hook portion 1330 may be configured to deform slightly to allow the end 1334 of the hook portion 1330 to hook to slide along the entry guide 1000 when the latch 1300 is rotated to the unlocked position. When the latch 1300 is in the unlocked position, the inlet guide 1000 can be pulled out of the inlet 820 without the use of a tool.

[00158] Although not illustrated, another embodiment of a mechanism for holding the inlet and outlet rails 1000, 1100 within the inlet 820 and outlet 822, respectively, may be pull actuators. The pull actuators may be substantially similar to the sliding actuators 900, but the spring 926 may have a different spring constant that biases the pull actuators toward the rear side 802 of the wire feeder 310 to secure the entry and exit guides 1000, 1100. In this embodiment the welder will need to pull the pull actuators out of the actuator holes 824(1), 824(2) to disengage the pull actuators on the input and output rails 1000, 1100. When the pull actuators are pulled out of the holes 824(1), 824(2 ) of the actuators, the inlet and outlet guides 1000, 1100 can be pulled out from the inlet 820 and outlet 820, respectively, without the use of a tool.

[00159] In FIG. 14A, 14B, 14C, 14D, 14E and 14F show a replacement cable connector 134 and the steps of replacing the first replacement cable connector 134 (eg, Euro plug) with a second replacement cable connector 134' (eg, TWECO connector). While Fig. 14A and 14B illustrate the first replacement cable connector 134, the discussion of the first replacement cable connector 134 applies to the second replacement cable connector 134' since the two connectors 134, 134' are structurally similar to each other.

[00160] As best illustrated in FIG. 14A, 14B, 14C and 14D, a replaceable cable connector 134 is configured to connect to the output side 806 of the wire feeder 310. Although not illustrated, the first end 1110 of the output guide 1100 that extends from the output side 806 of the wire feeder 310 may be at least partially received by the replacement cable connector 134 when the replacement cable connector 134 is coupled to the wire feeder 310. The replacement cable connector 134 may be constructed from electrically conductive materials.

[00161] As best illustrated in FIG. 14A and 14B, the replacement cable connector 134 includes a generally cylindrical body 1400 that includes a first end 1402, an opposing second end 1404, and a side wall 1406 extending from the first end 1402 to the second end 1404. The first end 1402 of the replacement cable connector 134 may serve as the connecting end 1410 and may include four holes 1412, 1414, 1416, 1418. The first outlet 1412 of the connecting end 1410 of the replacement cable connector 134 may be larger in diameter than the other three holes 1414, 1416, 1418, where the first outlet opening 1412 may extend through a removable cable connector 134 from a first end 1402 to a second end 1404. The first outlet 1412 may be configured to transfer welding wire through a removable cable connector 134 to a torch cable 62 (not shown) connected to the connecting end 1410. The second and third outlets 1414, 1416 may be electrical outputs configured to transmit electrical signals (eg, start signals) to and from a burner cable 62 (not shown). The fourth outlet 1418 may be a gas outlet configured to allow a flow of shielding gas to a torch cable 62 (not shown). Unlike the first embodiment of the removable cable connector 134, as illustrated in FIG. 14F, the second embodiment of the replaceable cable connector 134' illustrated in FIG. 14E includes a single opening 1419 that may be configured to transmit welding wire, electrical signals, and shielding gas to a torch cable 62 (not shown).

[00162] As best illustrated in FIG. 14A, 14B and 14C, the second end 1404 of the replaceable cable connector 134 may include a flange 1420 that includes two mounting holes 1422. These mounting holes 1422 may coincide with mounting holes 828 located on the second side 806 of the first housing portion 810 of the feed mechanism 310 wire. The mounting holes 1422 may be configured to receive fasteners 1470 that connect the replaceable cable connector 134 to the wire feed mechanism 310 .

[00163] As further illustrated in FIG. 14A and 14B, a gas inlet connection 1430 extends outwardly from a side wall 1416 between the first and second ends 1402, 1404 of a removable cable connector 134. A gas cable (not shown) within the wire feeder 40 may be connected to both a gas inlet connection 1430, and with the gas connector 356 of the connection panel 350. The shielding gas received by the gas inlet connection 1430 can flow through the replaceable cable connector 134 to the gas outlet 1418. As best illustrated in FIG. 14B, an electrical connector 1440 extends outward from a side wall 1416 of the replacement cable connector 134 between the first and second ends 1402, 1404, but is offset from the gas inlet connection 1430. An electrical connector 1440 of the replacement cable connector 134 is configured to connect to the lower busbar 342 (as illustrated in FIG. 7D) such that the replacement cable connector 134 receives welding power from the lower busbar 342. The replacement cable connector 134 may be configured to transferring the resulting welding power to the torch cable 62 (not shown) through a contact of the connecting end 1410 of the replacement cable connector 134 with a mating contact of the torch cable 62.

[00164] When the replacement cable connector 134 is coupled to the output side 806 of the wire feeder 310, an insulator 1450 may be positioned between the wire feeder 310 and the replacement cable connector 134. As best illustrated in FIG. 14C, insulator 1450 includes a center hole 1452 and a pair of mounting holes 1454. When coupled to the wire feeder 310, the center hole 1452 may be aligned with the outlet hole 822 of the wire feeder 310, while the mounting holes 1452 may be aligned with the mounting holes. holes 828 of the wire feed mechanism 310. In addition, the center hole 1452 can also be aligned with the first outlet 1412 of the replacement connector, while the fastening holes 1452 can be aligned with the fastening holes 1422 of the flange 1420 of the second end 1404 of the replacement cable connector 134. Fasteners 1470 can be inserted through the fasteners holes 1422 of the replacement cable connector 134 and mounting holes 1454 of the insulator 1450 to removably attach the replacement cable connector 134 and insulator 1450 to the wire feed mechanism 310. Thus, the insulator 1450 may be sandwiched between the wire feeder 310 and the replacement cable connector 134 and may be configured to isolate the wire feeder 310 from heat and/or electrical charge carried by the replacement cable connector 134.

[00165] As best illustrated in FIG. 14C and 14D, when the replaceable cable connector 134 is connected to the wire feeder 310, the first end 1402 of the replaceable cable connector 134 passes through the hole 133 of the removable panel 132 of the cover of the first connection panel 131, which is located on the front side 100 of the wire feeder 40. The torch connector socket 1460 may also be located within an opening 133 of the cover release panel 132 that surrounds the first end 1402 of the replacement cable connector 134. The torch connector socket 1460 may be made of an elastic, flexible and insulating material such as rubber. The torch connector receptacle 1460 may be configured to at least partially receive a connector of a torch cable 62 (not shown) when coupled to a replacement cable connector 134. The torch connector receptacle 1460 may include a central hole 1462 configured to receive and surround the first end 1402 of the replacement cable connector 134. The torch connector receptacle 1460 may also include mounting holes 1464 that may be configured to align with mounting holes on the cover access panel 132. The mounting holes 1464 may be configured to receive fasteners 1472 to removably secure the burner connector socket 1460 to the cover removable panel 132 .

[00166] To replace the first embodiment of the replacement cable connector 134 with the second embodiment of the replacement cable connector 134' or vice versa, the cover removable panel 132 is removed from the first connection panel 131, and the torch connector socket 1460 is removed from the cover removable panel 132. The lower bus bar 342 and the internal gas cable may then be disconnected from the electrical connector 1440 and the gas inlet connection 1430, respectively. The fasteners 1470 can then be removed from the fastening holes 1422, 1454 of the replacement cable connector 134 and the insulator 1450, respectively. A second embodiment of a replacement cable connector 134' (i.e., a TWECO connector) may then be attached to the insulator 1450 and wire feeder 310 via fasteners 1470. The internal gas cable may then be connected to the gas inlet connection 1430' while lower bus bar 342 may be connected to electrical connector 1440'. Before attaching the cover removable panel 132 to the first connection panel 132, the torch connector socket 1460 may be rotated 180 degrees so that the torch connector socket 1460 can receive a torch cable connector 62 compatible with the second embodiment of the replacement cable connector 134' (as shown in FIG. 14E and 14F). After the torch connector socket 1460 has been rotated and secured to the cover release panel 132 via fasteners 1472, the cover release panel 132 is connected to the first connection panel 131 such that the torch connector socket 1460 surrounds the first end 1402' of the second embodiment of the replacement cable connector 134'. In some embodiments, detaching the torch connector socket 1460 from the cover access panel may be the first step performed, while attaching the torch connector socket 1460 may also be the last step performed. In some configurations, when the second embodiment of the replacement cable connector 134' is installed on the wire feeder 40, it may be necessary to use an additional connector 136 of the first backplane 131 because the second embodiment of the replacement cable connector 134' does not contain as many exit holes as the first embodiment. implementation 134.

[00167] In FIG. 15A and 15B illustrate a wheeled carriage 1500. The wheeled carriage 1500 may include a support frame 1510 and a set of wheels 1520 coupled to the support frame 1510. The set of wheels 1520 may support the support frame 1510 above a support surface. The wheeled carriage 1500 may be coupled to one of the hatches 170, 180. As explained above with respect to FIGS. 6B, when the wear plates 202(1), 202(2) are removed from the hatch 170, 180, a series of mounting holes 208 are exposed. The support frame 1510 of the wheeled cart 1500 can be attached to one of the hatches 170, 180 through the mounting holes 208. As illustrated in Fig. 15B, the wheeled cart 1500 may be coupled to the second hatch 180 such that the wire feeder 40 can be mounted horizontally on the second side 110 where the wheeled cart 1500 supports the wire feeder 40 above the support surface.

[00168] In the foregoing detailed description, reference is made to the accompanying drawings, which form a part thereof, in which like reference numerals denote like parts throughout, and in which there are shown by way of illustration certain embodiments which may be practiced. It should be understood that other embodiments may be used and design or logical changes may be made without departing from the scope of the present invention. Accordingly, the foregoing detailed description is not to be construed as limiting, and the scope of the embodiments is determined by the appended claims and their equivalents.

[00169] Aspects of the present invention are disclosed in the description herein. Alternative embodiments of the present invention and their equivalents may be developed without departing from the spirit or scope of the present invention. It should be noted that any discussion herein regarding “one embodiment,” “an embodiment,” “an exemplary embodiment,” or the like, indicates that the described embodiment may include a particular feature, structure, or characteristic, and that such a particular feature, structure or characteristic may not necessarily be included in every embodiment. In addition, references to the above do not necessarily include reference to the same embodiment. Finally, whether or not explicitly described, one of ordinary skill in the art will readily appreciate that each of the specific features, structures, or characteristics of these embodiments may be used in conjunction with or in combination with the characteristics of any other embodiment discussed herein .

[00170] The various operations may be described as multiple discrete acts or operations in a manner that is most helpful to understanding the claimed subject matter. However, the order of description does not mean that these operations are necessarily order dependent. In particular, these operations may not be performed in the order in which they are presented. The described operations may be performed in a different order from the described embodiment. In additional embodiments, various additional operations may be performed and/or the described operations may be omitted.

[00171] For purposes of this disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For purposes of this disclosure, the phrase "A, B and/or C" means (A), (B), (C), (A and B), (A and C), (B and C) or (A, B and C).

[00172] The terms “comprising,” “including,” “having,” and the like, when used with respect to embodiments of the present disclosure, are synonymous.

[00173] It should be understood that terms such as "left", "right", "top", "bottom", "front", "rear", "side", "height", "length", "width" , “upper,” “lower,” “inner,” “outer,” and the like, which may be used herein, merely describe reference points or parts, and do not limit the present invention to any particular orientation or configuration. Additionally, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be considered as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the present invention.

[00174] While the disclosed inventions are illustrated and described herein as being embodied in one or more specific examples, they are not intended to be limited to the details shown, since various modifications and design changes may be made thereto without departing from the scope of the invention. the scope of these inventions and falling within the scope and range of equivalents of the claims. In addition, various features of one embodiment may be included in another of the embodiments. Accordingly, it is appropriate that the appended claims be read broadly in accordance with the scope set forth in the following claims.

Claims (15)

1. A device for feeding wire into a welding device, comprising components of a wire feeding mechanism, wherein the welding device comprises: an outer body portion having at least a front side, an upper side, a rear side and a bottom side, and defining a cavity; And an inner housing portion located within a cavity of the outer housing portion such that an intermediate space is located between the outer housing portion and the inner housing portion, the inner housing portion having at least a front side, an upper side, a rear side, and a lower side and defining an inner a cavity in which components of the wire feed mechanism of a welding device are located, with a portion of one of the components of the wire feed mechanism located in the intermediate space. 2. The wire feeding device of claim 1, wherein an upper side of the inner housing portion includes an opening and a lower side of the inner housing portion includes an opening. 3. The wire feeding device of claim 1, wherein an upper side of the inner body portion includes an opening, a lower side of the inner housing portion includes an opening, and the intermediate space, the upper side opening, and the lower side opening provide a closed-loop air flow for circulating air from the interior cavity of the inner housing portion through the intermediate space and back into the interior cavity of the inner housing portion. 4. The welding wire feeding apparatus of claim 1, wherein an upper side of the inner body portion includes an opening, a lower side of the inner housing portion includes an opening, and the intermediate space, the upper side opening, and the lower side opening provide a closed loop air flow for circulating air from the inner cavity of the inner body portion through the intermediate space and back to the inner cavity of the inner housing portion, and the heat of the air flowing through the intermediate space is dissipated through the outer body portion. 5. A device for feeding wire into a welding device according to claim 1, wherein the outer body part has a first structural rigidity, and the inner body part has a second structural rigidity, wherein the first rigidity is less than the second rigidity. 6. The device for feeding wire into a welding device according to claim 1, wherein a portion of one of the components of the wire feeder located in the intermediate space is a portion of a conductive busbar configured to conduct electric current, with the first portion extending through the intermediate space, and a second portion extending into the inner cavity of the inner housing portion through an opening located in the lower side of the inner housing portion, wherein the busbar has a first end located inside the inner cavity and a second end located inside the intermediate space. 7. A device for feeding wire into a welding device according to claim 6, additionally containing: a cable connector extending through the front side of the outer housing portion and connected to the second end of the busbar. 8. A device for feeding wire into a welding device according to claim 6, in which the conductive busbar is the first conductive busbar, and the welding device further comprises: a hole located in the upper side of the inner housing portion; And a second busbar with a first portion extending through the intermediate space and a second portion extending into an internal cavity of the inner housing portion through an opening in the upper side, the second busbar having a first end located within the inner cavity adjacent the first end of the first busbar, and a second end located inside the intermediate space adjacent the rear side of the outer housing portion. 9. A device for feeding wire into a welding device according to claim 8, wherein the second end of the second conductive busbar is connected to an additional connector extending through the rear side of the outer housing portion. 10. The device for feeding wire into a welding device according to claim 6, wherein the first end of the second busbar is connected to a power connector that is connected to the power cable, and is configured to receive welding power from the power source.

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