# Patent

## Title
Connection block for integral handle

## Abstract

The present invention includes a multi-use welding gun body configured for use in multiple locations along a welding gun assembly. In a particular embodiment, the multi-use welding gun body includes an enclosure forming an exterior surface of the body, the enclosure configured for both receiving a welding wire and a power source and directing the same toward a torch and having a first enclosure end with a wire-receiving aperture extending to an internal block-receiving cavity, the wire receiving aperture shaped to selectively receive a torch and an extension having an orifice containing both welding wire and shielding gas. The block-receiving cavity of the enclosure extends axially with a non-circular profile to a cable-receiving cavity within the housing, the cable-receiving cavity extending longitudinally to the second enclosure end. The second enclosure end includes an aperture forming an end of the cable-receiving cavity. A removable block is positioned within the block-receiving cavity.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/274,953, filed on Nov. 15, 2005, now pending.


TECHNICAL FIELD
The invention relates to the art of electric arc welding and more particularly to an improved handle for a welding gun between a wire feeder and a torch for the welding operation.
BACKGROUND OF INVENTION
In electric arc welding, a welding gun is a flexible, elongated element having a rear end connected to a wire feeder and a front end for a welding torch. The gun includes an elongated flexible conduit directing current and shielding gas from the wire feeder to the welding torch. Such a mechanism is employed for hand held welding and for robotic controlled welding in the trade.
The torch includes a contact tip through which the welding wire is directed from the wire feeder through the flexible tube to the welding operation. This tip is supported in a conductive cylindrical assembly receiving power from the wire feeder.
Shielding gas is directed from a diffuser in. the cylindrical assembly into a chamber defined by an outer nozzle through the nozzle into the area around the contact tip so the shielding gas forms a protective layer between the molten metal of the welding operation and atmosphere. All of these requirements of a torch require complex machined components at the end of the torch which substantially increases the cost and adversely affects the operability of the torch during the welding operation. Furthermore, the welding operation itself creates spatter, especially during short circuit conditions so the forward end of the torch including the contact tip and diffuser is subject to substantial deterioration over time caused by spatter together with the tremendous arc temperature involved in the welding operation.
Shielding gas is directed into the welding operation from diffuser orifices circumferentially spaced around the torch and directed ultimately to the contact tip at the welding operation. Consequently, torches have diffuser orifices for shielding gas; however, these orifices must be oriented to prevent unwanted cavitation. It has been found that these orifices should be as close as possible to the welding operation. Such closeness drastically increases the tendency for spatter to affect the laminar flow of shielding gas from the diffuser orifices.
Robotic assemblies are commonly used with welding guns. Previously, when robotic gun assemblies were dismantled, the down time was extensive because there was no quick and easy means to precisely reassemble the robotic gun. A previous example of a keyed alignment system for a welding torch used with a robotic gun assembly is shown in U.S. Pat. No. 5,451,117. A mounting arm which provides for various methods of changing position of the welding gun with respect to the robotic arm and the position of the gun with respect to its housing as well as providing easy disassembly of the gun from the robotic arm is described in co-pending application Ser. No. 11/178,819, filed on Jul. 11, 2005. Hex end structures for the torch end and welding wire feeder and are shown and described in co-pending application Ser. No. 11/268,085, filed on Nov. 7, 2005.
Furthermore, a welding gun which allows for various positions of the forward end and rear end of the gun is needed without complete disassembly of the gun. Accordingly, it is considered desirable to provide a welding gun which allows various positions of the welding gun with respect to the robotic assembly and with respect to the handle without completely disassembling either the gun or the robotic arm assembly. Also, providing a handle which allows for ease in assembly and disassembly of the welding gun as well as providing access to the internal components of the gun at either the welding torch end or wire feeder end is also desired.
SUMMARY OF THE INVENTION
The present invention is directed to a welding gun. In particular, the invention is directed to a welding gun having an integral handle adjacent a welding torch and an integral handle adjacent a welding wire feeder.
In accordance with one aspect of the invention, a welding gun assembly, for directing a welding wire toward a workpiece has a torch at a forward portion of the gun, a welding wire feeder at a rearward portion of the gun, and a handle positioned adjacent the wire feeder. The handle has a first cylindrical portion and a second hexagonally shaped portion adjacent the first cylindrical portion. The hexagonal portion has a first opening and a second opening adjacent the first opening. The handle further has an extension member with an opening therein and a first conduit connected to the cylindrical portion of the handle.
In accordance with another aspect of the invention, a handle for use with a welding gun assembly for applying welding wire to a workpiece, has a first cylindrical portion and a second hexagonal portion. The second hexagonal portion has a first opening and a second opening adjacent the first opening and an extension member with an opening therein.
In accordance with yet another aspect of the invention, a handle assembly for use with a welding gun assembly for applying welding wire to a workpiece, has a handle with a hexagonal shaped portion and a cylindrical shaped portion and an adapter which is attached to the cylindrical shaped portion. The adapter has a first external diameter portion having grooves thereon to receive a coiled spring.
One advantage of the present invention is the provision of providing an integral handle without the need for screws or other fasteners. The handle is inserted into a conduit and clamped or threaded into place.
Another advantage of the present invention is the provision of providing an internal handle at either or both of the torch and wire feeder ends of the welding gun assembly.
Yet another advantage of the present invention is the provision of the integral handle being reversible or able to be installed in positions 180 degrees apart.
Still another advantage of the present invention is the provision of an integral handle having an opening formed therein to provide access to the internal components or a switch for the welding gun.
Yet another advantage of the present invention is the provision of an integral handle formed of two halves which enable the handle to be easily assembled, and installed and removed from the welding gun.
Still another advantage of the present invention is the provision of providing a coiled spring within the conduit and within an adapter which is installed into the integral handle to prevent kinking of the conduit hose.
Still other advantages and aspects of the invention will become apparent through the following description and the accompanying drawings.



BRIEF DESCRIPTION OF DRAWINGS
The invention may take form in certain components and structures, a preferred embodiment of which is illustrated in the accompanying drawings wherein:
FIG. 1 is a side elevational view of a welding gun with integral handles adjacent a torch end and adjacent a welding wire feeder end;
FIG. 2 is a side elevational view in partial cross section, of the integral handle adjacent the welding wire feeder of FIG. 1;
FIG. 3 is a cross-sectional view through line 3-3 of FIG. 2;
FIG. 4 is a cross-sectional view through line 4-4 of FIG. 2;
FIG. 5 is a cross-sectional view through line 5-5 of FIG. 2;
FIG. 6 is a cross-sectional view through line 6-6 of FIG. 2;
FIG. 7 is a side-elevational view, in partial cross-section of the integral handle adjacent the welding torch of FIG. 1;
FIG. 8 is a cross-sectional view, along line 8-8 of FIG. 1;
FIG. 9 is an exploded perspective view of the integral handle of FIG. 7;
FIG. 10 is a side elevational view, in partial cross-section, of an integral handle in accordance with an alternate embodiment of the present invention; and,
FIG. 11 is an exploded perspective view of the integral handle of FIG. 10.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The apparatus shown in the accompanying drawings and described below are examples which embody the invention. It should be noted that the scope of the invention is defined by the accompanying claims, and not necessarily by specific features of exemplary embodiments.
For a welding operation of the type which the invention is concerned, it is the usual practice to provide a service station. This service station provides: a welding current of electricity; anti-oxidizing gas; a motor for feeding welding wire to the weld; and, optionally, a vacuum source for extracting fumes.
Referring now to FIG. 1, a robotic arm assembly generally designated by the numeral 10 includes a welding gun mount arm 12, a welding gun front or first integral handle 14 and a welding torch assembly 16. The gun mount arm 12 is a precision made instrument, typically manufactured from an aluminum alloy, preferably from 6061 aluminum alloy or the like. The gun mount arm 12 of the preferred embodiment is rotatably secured at a distal end 13 to a remote robotic machine arm 15. The gun handle 14 is preferably made of a plastic that is capable of maintaining its shape under tight clamping pressure. The handle is installed at a first or front end of the gun assembly near the torch. A cylindrically shaped gun housing 18, preferably made of brass, is installed at a second, or rear end of the gun assembly adjacent a welding wire feeder assembly 19. A second integral handle 17, also formed of plastic, is installed adjacent housing 18.
The welding torch further includes a gooseneck 20 which can be an insulated, thick walled copper conductor tube that is wrapped in an aluminum or stainless steel jacket that is capable of dissipating heat quickly. The gooseneck extends from the front handle 14. Although the gooseneck 20 as shown in FIG. 1 is bent at a particular angle, the gooseneck may be manufactured to be straight or bent at any desired angle. The torch of the preferred embodiment further comprises a thick walled nozzle 21 machined from hard drawn copper and typically has a highly conductive copper tip. The arrangement of the nozzle 21 is conventional and accordingly is not described in detail herein.
Referring now to FIG. 2, an anti-oxidizing shielding gas, such as argon, carbon dioxide, or other gas as required, is fed into the housing 18, via a port 23. A tube 31 is threadably connected via nut 28 to the port 23. A conventionally used power line 24 is further connected to the wire feeder 19 via a bolted connection 25. The wire feeder housing is secured to the housing 18 via a bolt or other suitable fastener 33 threadably inserted into an opening of feeder housing 19.
Welding wire 26 is inserted into the housing 18; the wire is on a set of motorized reels in wire feeder 19; whereby the wire may be fed forward controllably, in a conventional manner. The wire 26 may be received inside a close-coiled helical spring 30 (FIG. 3), which serves as a guide for the wire on its passage to the welding torch. The above-described arrangements for supplying the welding current, the welding wire, and the gas, into the flexible conduit follow conventional practice as is well known in the welding art.
Continually referring to FIG. 2, housing 18 has a hollow internal cavity 40 for receiving conduit 50. Conduit 50, preferably formed of brass, has an opening formed therein for receiving welding wire 26. The conduit has a grooved section 52 which has a plurality of openings 54 spaced approximately 90° apart. The holes serve as passageways for gas which enters the housing via tubing 31 into opening 37 (FIG. 3) about welding wire 26. A pair of O-rings 56, 58 or other suitable sealing material is received within grooves 57 of the conduit to seal and prevent gas from traveling or escaping into the cavity 40 of the housing 18. The conduit 50 also has a hexagonal shaped portion 59 which is selectively received by a corresponding hexagonal shaped opening 42 of housing 18.
The hexagonal shape of the conduit 50 allows the welding torch to be installed in different positions in the housing. Specifically, the hexagonal portion 59 has six holes 60 spaced approximately 60° apart formed in walls 63 of the conduit, as seen in FIG. 2. The conduit 50 is secured into position with respect to the housing 18 by bolt 61 or another suitable fastener. Bolt 61 extends through opening 62 formed in arm 64 extending radially outwardly from housing 18. The bolt is received by one of the openings 60 in hexagonal portion 59 as shown in FIG. 2.
Shielding gas travels through tube 31 into cavity 40 of housing 18 and then into the spaced apart holes 54 in groove 52. The gas then travels through opening 37 surrounding the wire 26 and spring 30. The wire initially passes through an opening 65 in a separate conduit 66 which is secured to an end member 67 of conduit 50.
Referring to FIG. 3, cylindrical end member 68 of conduit 50 extends into an opening 69 formed by two halves' 70, 72 of integral handle or sleeve 17. Integral sleeve 17 is preferably formed of plastic and is formed by two halves 70 and 72.
The sleeve further has a first portion 80 which is hexagonally shaped and is generally solid with opening 69 formed adjacent walls 82, 84 of sleeve halves 70 and 72. The sleeve further has walls 86, 88, 90, and 92 which form the hexagonal shape of portion 80.
Referring to FIGS. 2 and 4, adjacent to hexagonal portion 80 is second portion 94 which also is hexagonally shaped but has a hexagonal opening 96 formed by walls 82, 84, 86, 88, 90, and 92 of halves 70 and 72. Hexagonal opening 96 is adapted to receive block member 98 which is hexagonally shaped as well. Block 98 is preferably formed of brass and has walls 83, 85, 87, 89, 91, and 93 which form a hexagonal configuration.
Block 98 is hexagonally shaped and is selectively received within hexagonally shaped opening 96 of sleeve 17. Thus, block 98 can be positioned in anyone of six positions approximately 60 degrees apart with respect to the sleeve 17.
Referring to FIG. 4, a metal or plastic clamp 100 extends around outer walls 82, 84, 86, 88, 90, and 92 of sleeve 17. The clamp has an opening 102 formed by walls 103, 105, 107, 109, 111, and 113 which conforms to the hexagonal shape of the sleeve and the block 98. The clamp has two opposing ends 104, 106 which are secured together via a bolt fastener 108 which extends through openings 110, 112 formed in arms 114, 116. The clamp further secures the two halves 70, 72 of the integral handle 17 together. The handle may be positioned in one of six positions 60 degrees apart with respect to the clamp.
Referring to FIGS. 2 and 5, pipe-spigots 120, 122 are formed on feed ends of conventionally used power cables 124, 126 which extend through a welding gun plastic flexible sleeve 130 which extends between integral handle 17 and handle 14. The pipe-spigots are inserted into sockets 132, 134 formed in end wall 136 of first block 98. Plug ends of the pipe-spigots can be taper fit into the sockets 132, 134. Referring to FIG. 2, first block 98 also has a conically-shaped socket 137 for receiving a tip or pipe-spigot 138 of a welding wire feed tube 140.
When the plug-ends of the pipe-spigots are inserted tightly in the sockets 132, 134, not only are the pipe-spigots secured very well mechanically to the block, but also there is an excellent, low resistance, electrical contact between the pipe-spigots and the block. A length of flexible electrical cable is brazed or soldered into a hole in the pipe-, spigots.
As compared with a single cable, dividing the electrical duty between two cables means that each cable can be a little less than half the current-carrying cross-section than the corresponding single cable. The reason each half-cable can be a little less than half the size is that each half-cable is contained in its own respective jacket, whereby cooling of the cable can be enhanced.
When only a single cable was provided, as in conventional designs, the conduit could be quite stiff. As a result, the welding operator found it quite tiring to operate the torch through a working day.
Splitting the cable into two and using two smaller-than-half cables, results in a greater improvement in physical flexibility and manipulability to the conduit; so much so as to extend by hours the period the operator can work comfortably.
Referring to FIG. 5, in order to ensure the pipe-spigots 120, 122, 138 are pressed firmly into the sockets 132, 134, 137, a plate or draw-ring 142, preferably formed of steel, is provided as shown in FIG. 5. The approximately hexagonal shaped draw-ring has substantially U-shaped slots or cut-outs 144, 146, 148 which engage complementary recesses defined between collars provided on the pipe-spigots.
The draw-ring 142 is separate from the block 98 and can move slightly with respect to the block to adjust the position of the pipe-spigots. When the draw-ring is moved to the right, it urges the pipe-spigots tightly into the sockets 132, 134, 137 in the block 98; when the draw-ring is forced to the left, it disengages the pipe-spigots from the block. The draw-ring 142 is moved to the right by tightening a bolt 150 which is inserted into an opening 151 in the ring and into a corresponding opening 152 in the block. To move the draw-ring to the left, the bolt 150 is slackened, and then the head of the bolt may be tapped to the left to drive the pipe-spigots free from the sockets. (The angle of the taper in the sockets is such that the taper is self-locking). The bolt 150 is screw-threaded into the draw-ring 142 and passes through corresponding plain hole 152 in the block 98.
As described, the cable and wire assembly includes the welding wire 26 inside its guide spring surrounded by tubing 140; and the two electrical cables inside their respective tubes 124, 126. It will be noted that the three flexible pipes or tubes 124, 126, 140 can all have respective central internal “cores” of metal; these “cores” serve to provide excellent resistance to kinking of the pipes and tubes and to other types of mechanical failure. The entire wire and cable assembly is enclosed in sleeve 130.
The wire and cable assembly is therefore very sturdy in the sense of being able to resist the abuse which is always likely to be imposed upon it in a practical welding shop, especially abuse such as snagging, twisting, and the like. On the other hand, none of the components of the wire and cable are thick or heavy, and therefore the assembly is light in weight, and is comparatively very flexible. It is easy for the operator to carry and manipulate a welding torch supported on such an assembly for long periods.
The sleeve further has elongated slots 154 and ribs 156 of varying lengths which extend along a longitudinal length of the sleeve halves. The sleeve has a cylindrical shape portion 158 through which the slots and ribs extend. Corresponding ribs and slots matingly engage each other to snap or secure halves 70, 72 of the handle together.
Referring to FIGS. 5 and 9, a projecting or extending member 160 is formed on an outer surface 162 of the cylindrical portion 158 and includes two halves 164, 166. Each half has a groove 168, 170 formed therein. The projecting member is shown to be rectangular in shape; however, other configurations can be used without departing from the scope of the invention. Referring to FIG. 9, each half also has an opening 177 formed by three side walls, 171, 172, 173, 174, 175, 176 which together form a generally rectangular shaped opening. The opening permits access to the internal components of the welding gun, such as the power cables and the welding wire tubing. Also, the trigger for the welding gun handle assembly may be positioned within the opening. A trigger can be included in the handle, which, when operated, activates the welding current, starts the wire feed-motor, etc., back at the service station.
As shown in FIGS. 5 and 9, a cap 180 may be slidably inserted into the grooves 168, 170 of the sleeve. Flange 182 of the cap is inserted into the grooves and the cap covers the opening 177. The cap 180 has a ridge or flange 182 which extends around an outer surface thereof. The flange is slidably received within grooves 168, 170 of the sleeve. The cap further has a top portion or housing 184 which has a hollow cavity 186 therein. The housing 184 can enclose internal components for a trigger assembly such as wiring, conduit tubing, etc. The cap provides easy access to the internal cavity of the sleeve and to the power lines and welding wire tube.
Referring to FIGS. 2 and 6, the cylindrical portion 158 of the sleeve has a distal end 188 which is secured to or engages an end portion 190 of conduit 130. A collar or flange 191 extends from the sleeve and abuts the end portion 190 of conduit 130. As seen in FIGS. 2 and 9, the sleeve can have a groove 192 formed between two outer walls 193, 195 at end 196 which matingly engages a corresponding rib 194 on an inner diameter of conduit 130. To secure the sleeve to the conduit, a conventional hose clamp 197, such as one made from metal or plastic, can be used to tighten around the outer surface of the sleeve to secure the sleeve or handle to the conduit 130. Thus, the handle or sleeve 17 may be secured to the conduit tube 130 without the need for screws or other fasteners.
The other, front or supply end of the welding gun adjacent to the torch, will now be described. The gooseneck 20 extends between the torch nozzle 21 and first or front housing 14. Referring to FIG. 7, a second block 200, also formed of brass, is secured to an end portion of second conduit 202 which extends from end 204 of the gooseneck. Block 200 has an opening 201 for receiving the welding wire 26 and spring 30.
A second sleeve 14 is essentially the mirror image of sleeve 17. That is, the sleeve or handle can be positioned in reversed positions 180 degrees apart on the welding gun. Accordingly, the detailed description of sleeve 17 also applies for sleeve 14. Sleeve 14 also has a hexagonal portion 212 and a cylindrical portion 214. Hexagonal portion has a cylindrical opening 216 for receiving conduit 202. A second hexagonal opening 218 formed by walls 209, 211, 213, 215, 217 and 219 receives walls 221, 223, 235, 227, 229 and 231 of hexagonal brass block 200. Block 200 can be positioned in one of six positions 60 degrees apart with respect to sleeve 14. A second draw ring 220 connected to block 200 by a bolt 275 receives pipe-spigots 222, 224 of power cables 124, 126 and pipe-spigot 226 of welding wire feed tube 140. A clamp 230 is used to hold the sleeve on a distal end 232 of conduit 130. Thus, the handle or sleeve 14 may be secured to the conduit tube 130 without the need for screws or other fasteners. Sleeve 14 also has extension 234 which has grooves 236 for receiving a cap 238 covering an access opening 239′. The handle and conduit can be easily disassembled by simply loosening and removing the clamp 197.
Referring to FIG. 8, a mounting bracket 240 receives the sleeve 200. The bracket has a hexagonally shaped opening 242 formed by walls 244, 246, 248, 250, 252, 254. The bracket has two walls 256, 258 which are substantially parallel to each other and form a gap therebetween so that the bracket can expand slightly to remove or install the sleeve 200 in the opening 242. Each wall 256, 258 has a threaded openings 260, 262 therein for receiving a fastener or threaded member 264 therethrough to clamp the sleeve within the mounting bracket. The bracket in turn is secured to mounting arm 12 by two bolts or fasteners 266 which extend through openings 270, 272 in bracket arm 274 into openings 276, 278 in arm 12.
The hexagonal shape of the sleeve 14 as well as the opening 242 of the mounting bracket allows the sleeve, and the welding torch to be positioned in one of six positions approximately 60 degrees apart with respect to the mounting bracket of a robotic arm 12. Such a robotic arm assembly is discussed in co-pending application Ser. No. 11/178,819, filed on Jul. 11, 2005.
The pipe-spigots may be secured into the block by means of the tapered sockets formed in end wall of block, or, alternatively, the pipe-spigots may be secured into a block by means of screw-threads. The block, preferably made of brass, and the plugs are brazed into the drilling as required: as a general rule in welding torches, the use of rubber seals should be avoided except where the sealed components have to be detachable. Because of the very tight restriction on the radial space envelope in the torch handle, the room available for the spigot-to-block connection, whatever its structure is severely limited. It is recognized that if this small space were occupied by a screw-thread connection, the constraints would be so tight that the screw-thread connection at that location would be unreliable. That is, if the pipe-spigot were secured into the block by means of a screw-thread connection, the screw-thread would be so small that there would be a danger that the thread would strip, even with just a small degree of abuse. It may be noted also that the components in question are “generally made of brass, which material has no great resistance to the stripping of threads if over-tightened.
The connection as described has good electrical properties. When assembled, the pipe-spigot becomes tightly wedged into the socket, which gives an excellent, large-contact-area, electrical connection for the heavy welding currents.
Preferably, the pipe-spigots at the service-station end should be identical to the spigots at the torch end. Although there is no premium on radial space at the service station end of the conduit, it is simpler to have components the same.
Although two electrical power pipes have been described, more than two may be provided. The draw-ring and draw bolt arrangement can be used to tighten more than two pipe-spigots into place (simultaneously) into suitable sockets.
Referring now to FIGS. 10-11, an alternative embodiment is shown. FIGS. 10 and 11 illustrate the addition of a coiled spring to the integral handle and to the conduit. The coiled spring is added to prevent or minimize kinking of the flexible conduit cable 300 as the conduit is moved by the robotic arm assembly.
More particularly, conduit 300, preferably formed of flexible plastic, has a spiraled groove 302 formed on an internal wall 301 of the conduit extending along the longitudinal length of the conduit. A coiled spring 304, preferably made of metal is installed within the conduit and is press fit or otherwise engages the groove 302 formed in the internal wall of the conduit. The spring provides resilience and rigidity to the conduit and allows the conduit to bend without kinking. The spring extends outwardly from an end wall 306 of the conduit and onto an end wall 308 of an adapter 310. The adapter is preferably formed of thermoplastic material. The adapter has end member 308 which has an outer diameter slightly less than an inner diameter of wall 301 of the conduit 300. The end wall 308 is inserted into end wall 306 of conduit 300. Adapter end 308 also has a spiraled groove 312 formed on an outer wall 314 of the end 308 corresponding to the groove 302 on inner wall 301 of the conduit. The adapter also has end 316 which includes walls 318 and 320 which have a groove 322 formed therebetween. Walls 318 and 320 have inner diameters which correspond to outer diameters of walls 325,326 of sleeve 328. Similarly, groove 322 has an inner diameter corresponding to the outer diameter of groove 330 of the sleeve.
The adapter has a plurality of slots 324 formed around the circumference of the adapter and through walls 318, 320 and groove 322 to enable the adapter to expand slightly to be installed onto and over the walls 325, 326 of sleeve 328.
Referring to FIGS. 10 and 11, the adapter end 308 is inserted into end 306 of the conduit until wall 316 abuts end 306 of the conduit. Then, a conventional hose clamp 332 is placed over the conduit end 306 and is tightened to secure the end of the adapter to the end of the conduit. End 316 of the adapter is installed over end 334 of the sleeve such that walls 318 and 320 aligns with walls 325, 326 and groove 322 aligns with groove 330 of the sleeve. Then, another hose clamp 340 is placed into groove 322 and is tightened to secure the adapter onto the sleeve.
One aspect of the integral handle is that the handle is secured to a conduit tube without the need for screws or other fasteners. The handle is inserted into the conduit and clamped or threaded into place. Another aspect of the internal handle is that it can be installed at either or both of the torch and wire feeder ends of the welding gun assembly. Yet another aspect of the handle is that the handle is reversible or able to be installed in positions 180 degrees apart. Still another aspect of the handle is an opening formed therein to provide access to the internal components or a switch for the welding gun. Yet another aspect of the handle integral handle is that it is formed of two halves which enable the handle to be easily installed and removed from the welding gun. Still another aspect of the handle is the provision of providing a coiled spring within the conduit and within an adapter which is installed into the integral handle to prevent kinking of the conduit hose.
The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

## Claims

1. A welding gun body comprising:
an enclosure forming an exterior surface of the body, the enclosure configured for both receiving a welding wire and a power source and directing the same toward a torch, the enclosure extending longitudinally between first and second enclosure ends;
the first enclosure end having an outer surface through which a wire-receiving aperture extends in a longitudinal direction from the first enclosure end to an internal non-circular first block-receiving cavity, the first block-receiving cavity shaped to selectively receive a first removable block, the first removable block extending inwardly along a longitudinal axis with an outer profile generally shaped to closely match the non-circular profile of the first block-receiving cavity, said first removable block comprising a welding wire conduit positioned therethrough, said conduit further accommodating a shielding gas;
the non-circular first block-receiving cavity of the enclosure extending axially in a longitudinal direction with a non-circular profile to a cable-receiving cavity within the housing, the cable-receiving cavity extending longitudinally toward the second enclosure end, said cable-receiving cavity comprising at least two cable conduits positioned within said housing;
the second enclosure end including a wire and shielding gas exit aperture, said second enclosure end in proximity to a second non-circular block-receiving cavity;
a removable second block positioned within the second block-receiving cavity, the removable second block extending axially inwardly with an outer profile generally shaped to closely match the non-circular profile of the second block-receiving cavity;
the second block having opposed ends, said second block also having a pair of wire-receiving and wire-exiting apertures extending axially between the opposed ends of the second block,
the first block end being arranged generally adjacent the aperture of the first enclosure end;
the second block being arranged generally adjacent the aperture of the second enclosure end, said second block further receiving two or more power cable-receiving apertures in addition to the wire-receiving aperture each of the two or more power cable-receiving opening form a socket for receiving a pipe-spigot of a corresponding power cable.

2. The welding gun body of claim 1, wherein
a portion of the exterior enclosure forms a contoured mounting surface for a robotic arm.

3. The welding gun body of claim 1, wherein
the enclosure includes an annular groove positioned along the exterior surface of the enclosure, the groove being positioned near the first end of the enclosure for receiving a conduit containing said shielding gas.

4. The welding gun body of claim 1, wherein
said enclosure comprises a flexible plastic having a coiled spring within a spiral groove.

5. The welding gun body of claim 1, wherein
the non-circular profile of the first and second cavities are hexagonal.

6. The welding gun body of claim 1 further comprising
an end plate generally positioned adjacent to and interior of at least one removable block within at least one block-receiving cavity,
the end plate comprising a plurality of slots for receiving two or more power cables and a welding wire cable.

7. The welding gun body of claim 1 further comprising
a threaded fastener for adjusting the position of an end plate relative to the block,
the fastener extending between the end plate and the block.

8. The welding gun body of claim 1, wherein
at least one of the removable blocks are formed of two halves,
each half extending longitudinally between the ends of the blocks.

9. The welding gun body of claim 1, wherein
the enclosure further comprises a user access opening extending between the exterior surface and the cable-receiving cavity within the enclosure and being positioned generally adjacent to the access opening.

10. The welding gun body of claim 9 further comprising
a removable cap selectively received by an extension member surrounding at least a portion of the access opening along the exterior surface of the enclosure.

11. A welding gun assembly for directing a welding wire toward a workpiece, comprising:
a torch positioned at a forward portion of the gun;
a gun body comprising an enclosure extending longitudinally between first and second enclosure ends, the torch being attached to the first enclosure end and the second enclosure end adapted to receive a welding wire cable and two or more power cables;
the first enclosure end including an aperture extending in a longitudinal direction of the enclosure from an outer surface to an internal block-receiving cavity;
the block-receiving cavity extending axially in a longitudinal direction with a non-circular profile to a cable-receiving cavity within the enclosure, the cable-receiving cavity extending longitudinally to the second enclosure end;
a removable block positioned within the block-receiving cavity, the block extending axially between first and second block ends and having a longitudinal profile generally matching the longitudinal profile of the block-receiving cavity,
the block also having a wire-receiving aperture extending axially between the first and second block ends,
the first block end being arranged generally adjacent the aperture of the first enclosure end;
the second block end having two or more power cable-receiving apertures;
two or more power cables extending into the second enclosure end, each of the two or more power cables extending into power cable-receiving apertures within the block each of the two or more power cable-receiving opening form a socket for receiving a pipe-spigot of a corresponding power cable.

12. The welding gun assembly of claim 11, wherein
a portion of the exterior enclosure forms a contoured mounting surface for a robotic arm.

13. The welding gun assembly of claim 11, wherein
the enclosure includes an annular groove positioned along the exterior surface of the enclosure, the groove being positioned near the second end of the enclosure for receiving a conduit containing welding wire and power cables.

14. The welding gun assembly of claim 11, wherein
said enclosure comprises a flexible plastic having a coiled spring within a spiral groove.

15. The welding gun assembly of claim 11 further comprising
an end plate generally positioned adjacent to the block within the cable-receiving cavity, the end plate comprising a plurality of slots for receiving power cables and a welding wire cable.

16. The welding gun assembly of claim 15 further comprising
a threaded fastener for adjusting the position of the end plate relative to the block, the fastener extending between the end plate and the block.

17. The welding gun assembly of claim 11,
the enclosure further including an access opening extending between the exterior surface and the cable-receiving cavity within the enclosure and being positioned along the exterior surface generally adjacent to the access opening.

18. The welding gun assembly of claim 17 further comprising
a removable cap selectively received by an extension member surrounding at least a portion of the access opening along the exterior surface of the enclosure.

19. A welding gun component comprising:
a flexible hose comprising two opposed ends, said hose comprising at least three internal channels, at least one of said channels communicating a welding wire and at least two of said channels communicating power originating from a single power source;
a first and second enclosure end at said ends of said hose, each of said enclosures removably attached to said ends;
each of said enclosures having hollow non-circular cavities disposed therein;
each of said non-circular cavities having a removable block positioned therein, an exterior profile of said removable block essentially conforming to said interior profile of said cavity;
said enclosure adjacent a wire feeding end of said flexible hose comprising at least one longitudinally and axially extending channel for ingress of a welding wire, said channel further in communication with a shielding gas channel at an interior location of said enclosure;
said enclosure adjacent a wire exiting end of said flexible hose comprising at least one longitudinally and axially extending channel for egress of said welding wire and said shielding gas;
each of said pair of enclosures having at least three sockets for receipt of a mating spigot from said flexible hose, one mating spigot and socket combination for said welding wire and shielding gas combination; and at least two other mating spigot and socket combinations for a pair of power cables; and
a means for tightening said mating spigot and socket combinations the first enclosure end having an outer surface through which a wire-receiving aperture extends in a longitudinal direction from the first enclosure end to an internal non-circular first block-receiving cavity, the first block-receiving cavity shaped to selectively receive a first removable block, the first removable block extending inwardly along a longitudinal axis with an outer profile, generally shaped to closely match the non-circular profile of the first block-receiving cavity, said first removable block comprising a welding wire conduit positioned there through, said conduit further accommodating a shielding gas;
the second enclosure end including an a wire and shielding, gas exit aperture, said second enclosure end in proximity to a second non-circular block-receiving cavity;
a removable second block positioned within the second block-receiving cavity, the removable second block extending axially with an outer profile generally shaped to closely match the non-circular profile of the second block-receiving cavity.

20. The welding gun component of claim 19 wherein
each of said pair of power cables is less than one-half of a single power cable.

21. The welding gun body of claim 1 wherein
each of the two or more power cables is less than one-half of a single power cable.

22. The welding gun assembly of claim 11 wherein
each of the two or more power cables is less than one-half of a single power cable.