Patent Description:
Generally, welding robots include one or more arms, a torch, and a wire feeder for feeding weld wire to the torch. The torch is disposed at a distal end of the robot and the wire feeder is disposed between a base of the torch and the distal end. A cable connects the wire feeder to the torch and provides one or more of electricity, weld wire, process gas, and cooling fluid from the wire feeder. Close contact between a power pin of the plug and receiving block of a socket is desirable for proper transfer of electricity and fluids from the wire feeder to the torch cable.

Typically, a user climbs up the robot to connect the torch cable to the wire feeder. The user inserts a plug of the torch cable into a socket of the wire feeder and holds it in place with one hand, while clamping the plug to a socket with the other hand. With both hands otherwise occupied with clamping/securing the torch cable to the wire feeder, the user does not have a free hand to steady herself while perched on the robot. The user may be unsteady on the robot and could fall off. Consequently, the user may not properly secure the plug of the cable with the socket resulting in inefficient transfer of electricity, kinking or jamming of weld wire, and/or leakage of fluids.

Moreover, typically, a liner is disposed in the plug and cable to protect weld wire fed through the connector. The liner can be installed in the cable by inserting the liner through the power pin of the plug. Once installed, the liner isolates weld wire from the electrical current and/or a fluid that flows through the power pin and cable. Often, the liner is held in place by a bolt that traverses the power pin and engages a tip of the liner. The bolt may be loosened or tightened with a tool, e.g., screw driver, allen wrench, etc., but over tightening of the bolt may cause damage to the liner, which may cause the weld wire to kink.

A plug assembly for an arc process device is disclosed in <CIT>. The plug assembly has a metal plug portion for electrically coupling to a welding machine. The plug portion extends from an insulated rear case that is coupled to a cable hose. A socket conveying electrical current, shield gas, and compressed air for an arc processing device is disclosed in <CIT>. The socket includes a cylindrical bore having two annular grooves for receiving the shielding gas and/or compressed air and contact clamp to grip a metal sleeve of a cable.

In view of at least the aforementioned issues, a connection system for efficiently and safely securing a liner within a torch cable, and/or connecting a torch cable to a power source and/or wire feeder are desirable.

According to a first aspect of the present invention, a multi-diameter power pin for a plug of a cable for an arc process system is defined in claim <NUM>.

Further preferred embodiments of the power pin are defined in the corresponding dependent claims.

According to a second aspect of the present invention, a socket for a multi-diameter power pin of a plug of a cable for an arc process system is defined in claim <NUM>.

Further preferred embodiments of the socket are defined in the corresponding dependent claims.

To complete the description and in order to provide for a better understanding of the present invention, a set of drawings is provided. The drawings form an integral part of the description and illustrate an embodiment of the present invention, which should not be interpreted as restricting the scope of the invention, but just as an example of how the invention can be carried out.

The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the invention. Embodiments of the invention will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the present invention. Embodiments of the invention are described with reference to a connector for a wire feeder and a welding torch cable, however embodiments are not limited thereto. For example, the connector may be used for connecting and transmitting power between any two components of a high-power system, such as a power source and a cable of a plasma cutting torch.

A conventional power pin of a plug for an arc processing operation (e.g., a welding or plasma cutting operation) generally includes only one or two portions having one or two diameters. For example, a conventional power pin may include an attachment portion for attaching to a cable and a second portion configured to be clamped into and receive one or more gases from a receiving block of a socket. Typically, the entire second portion is clamped in receiving block. That is, a clamp of the receiving block is configured to bear against of the second portion. The second portion generally includes surface features, such as one or more grooves, bores, and/or protrusions configured to receive one or more of process gases, seals, holder screws, etc..

When the conventional power pin is inserted into a receiving block of a socket, a user must hold the plug in place with one hand and clamp the second portion in the receiving block with a second hand. However, if one or more of surface features of the second portion are not be properly aligned with corresponding structures in the receiving block during this two-handed clamping operations, fluids used during the arc processing operation may leak from the plug and socket. Moreover, even if the second portion is properly aligned within the receiving block, one or more of the surface features may obstruct the clamp of the receiving block resulting in a loose connection between the power pin and receiving block. The loose connection may allow the plug to fall out and/or cause a poor electrical connection, resulting in power losses during operation.

Generally, the system and method for connecting a torch cable to a wire feeder presented herein include a plug having a multi-diameter power pin and a socket with a receiving block having a multi-diameter through hole, or bore, for receiving the power pin. The features of the power pin and receiving block allow a user to connect and secure the plug to the socket with one hand. For example, an engagement mechanism disposed in the power pin engages an inner surface of the receiving block in response to inserting the pin into the receiving block. The engagement mechanism maintains a position of the power pin while the user clamps and secures the power pin in the receiving block. Thus, with one hand, the user can insert the power pin into the receiving block and provisionally lock it with the engagement mechanism, let go of the torch cable, and lock the power pin in place with a clamp.

Moreover, a dedicated bearing portion of the power pin corresponding to dedicated clamping portion of the receiving block provides an improved electrical connection between the pin and receiving block as compared to conventional connectors. That is, the dedicated bearing portion and clamp provide unobstructed contact between the power pin and receiving block. Thus, electricity may be efficiently conducted between the receiving block and power pin without the drawbacks of the conventional power pin noted above.

Additionally, the power pin includes a central bore for receiving a liner that extends into the torch cable. The liner isolates a weld wire passing through the connector from an inner surface of the power pin and a conductor of the torch cable. A user can access the central bore of the power pin by removing a liner cap by hand, without using a tool, and insert the liner with the liner tip into the central bore. To secure the liner, the user can dispose the liner cap over the liner tip and a distal portion of the power pin, thereby clamping the liner tip between the liner cap and power pin. To access or replace the liner, a user can remove the liner cap, without a tool, to expose the liner tip and distal end of the power pin. Thus, the liner cap and liner can be easily installed, secured, and/or replaced without the drawbacks of the conventional liner and bolt arrangement noted above. Moreover, the liner cap shape assists in guiding the power pin into the receiving block and prevents weld wire from kinking.

Referring to <FIG>, a schematic diagram of an exemplary embodiment of a robot welding system <NUM>, according to an embodiment is depicted. The robot welding system <NUM> includes a robot <NUM> connected to a controller <NUM>, a wire feeder assembly <NUM>, a power source <NUM>, and wire spool <NUM>. The power source <NUM> is electrically coupled to the robot <NUM> and the torch <NUM> via the controller <NUM>, and the wire feeder assembly <NUM>, respectively. The power source <NUM> can provide power to components of the robot <NUM>, controller <NUM>, and the wire feeder assembly <NUM>, as well as a process current for an arc process (e.g., a welding or plasma cutting operation). Additionally, the power source <NUM> may provide a shield gas and/or a process gas for the plasma arc process to the wire feeder. The controller <NUM> controls the movement of the robot <NUM> and the plasma arc process. A wire supply <NUM> provides weld wire to the wire feeder assembly <NUM>. The wire supply <NUM> may be a bulk pack <NUM> or a spool <NUM>. In some implementations, the spool <NUM> is disposed in the wire feeder assembly <NUM>.

In the depicted embodiment, the robot <NUM> includes a base <NUM>, a first arm <NUM> pivotably attached to and extending from the base <NUM>, and a second arm <NUM> pivotably coupled to the first arm <NUM>, opposite the base <NUM>. A torch <NUM> is disposed on a distal end <NUM> of the second arm <NUM>, and the wire feeder assembly <NUM> is disposed at a coupling between the first arm <NUM> and second arm <NUM>. However, this is just one example of a welding robot and the present application may be applicable to a wide variety of robots.

Regardless of the exact configuration of the robot and the location of the wire feeder assembly <NUM> on the robot, a torch cable <NUM> connects the torch <NUM> to the wire feeder assembly <NUM>. A connector <NUM> couples the torch cable <NUM> to the wire feeder assembly <NUM>. The connector includes a socket <NUM> disposed at the wire feeder assembly <NUM> (see <FIG>) and a plug <NUM> disposed on the torch cable <NUM> (see <FIG>). During a weld operation, the torch cable <NUM> transmits a process current, weld wire, and fluids (e.g., shield gas, process gas, and/or cooling fluid) from the wire feeder assembly <NUM> through the connector <NUM> and torch cable <NUM> to the torch <NUM>.

<FIG> is a side perspective view of a wire feeder assembly <NUM> according to an embodiment. The wire feeder assembly <NUM> includes an outer housing <NUM> having a front face <NUM> and a rear face <NUM>. The front face <NUM> includes a connector port <NUM> and a power port <NUM> that each define passageways through the front face <NUM> to an interior compartment <NUM> defined by the housing <NUM>. A divider wall <NUM> within the housing <NUM> divides the interior compartment <NUM> into a wire feeding side <NUM> and a control side <NUM>. The wire feeding side <NUM> houses a socket <NUM> of the connector <NUM> and a feeder <NUM> for pulling weld wire through a wire port <NUM> in the rear face <NUM>. The connector port <NUM> provides a passage for a plug <NUM> of the connector <NUM> to be inserted into the socket <NUM>. A conductor <NUM> (See <FIG>) for conducting arc process power can be inserted through the power port <NUM> and electrically coupled to the socket <NUM>, as is described below with reference to <FIG>.

The feeder <NUM> includes a plurality of wire rollers <NUM> for pulling the weld wire from a wire supply <NUM> through the wire port <NUM> and pushing the weld wire through the socket <NUM>. The control side <NUM> includes components and/or circuitry for receiving signals and controlling the feeder <NUM> based on the received signals. In some implementations, the components and/or circuitry may control one or more arc process parameters (e.g., process power, process current, voltage, process gas flow, shield gas flow, cooling fluid flow, wire feed speed, etc.).

<FIG> is a perspective view of a portion of the wire feeding side <NUM> of the interior compartment <NUM>. A receiving block <NUM> of the socket <NUM> is disposed between and aligned with the feeder <NUM> and the connector port <NUM>. The receiving block <NUM> is configured to receive the plug <NUM> of the connector <NUM> and the conductor <NUM>.

Referring to <FIG>, three configurations of the connector <NUM> are illustrated. The wire feeder assembly <NUM> accommodating the socket <NUM> has been omitted for clarity. In configuration C1, the plug <NUM> is separate and removed from the socket <NUM> (see <FIG> and <FIG>). The plug <NUM> of the connector <NUM> includes a distal end <NUM> and a proximal end <NUM> connected to the torch cable <NUM>. A multi-diameter power pin <NUM> is disposed at the distal end <NUM>. The socket <NUM> includes a receiving block <NUM> having a multi-diameter through hole, or central bore, <NUM> for receiving the power pin <NUM>.

In configuration C2 the plug <NUM> is inserted into the socket <NUM> but is not clamped in place or otherwise locked (see <FIG>). The power pin <NUM> provisionally engages an internal surface of the receiving block <NUM> defining the central bore <NUM> and holds the plug <NUM> in place. Consequently, the plug <NUM> cannot disengage the socket <NUM> on its own, but a user can remove the plug <NUM> by hand, if desired. The provisional engagement configuration C2 between the power pin <NUM> and receiving block <NUM> is discussed in detail below with reference to <FIG>.

In configuration C3, the socket <NUM> receives and clamps, or otherwise locks, the plug <NUM> in position with a quick release bolt <NUM> (see <FIG>). In the locked configuration C3, the receiving block <NUM> secures the power pin <NUM> in the central bore <NUM> such that the plug <NUM> cannot be removed from the socket <NUM> without damaging the connector <NUM> (i.e., irremovably locks the connector <NUM>). The locked configuration C3 between the power pin <NUM> and receiving block <NUM> is discussed in detail below with reference to <FIG>.

<FIG> and <FIG> depict the multi-diameter power pin <NUM> of the plug <NUM> with the torch cable <NUM> omitted for clarity. The power pin <NUM> is configured to receive arc process power (e.g., a weld or plasma cutting current), shield gases, arc process gases, and/or cooling fluid from the receiving block <NUM>. The power pin <NUM> is further configured to receive weld wire from the feeder <NUM>. A central bore <NUM> extends through the length of the power pin <NUM> along a longitudinal axis <NUM>. The central bore <NUM> provides a path through the power pin <NUM> for process and/or shield gases and weld wire. A liner <NUM> is disposed within the central bore <NUM>. The liner <NUM> comprises an elongated tube defining a conduit <NUM> for receiving the weld wire. Accordingly, the liner <NUM> isolates the weld wire from the inner surface of the power pin <NUM> and process and/or shield gasses flowing through the central bore <NUM>.

The power pin <NUM> includes a proximal portion <NUM>, an engagement portion <NUM> extending from the proximal portion <NUM>, a bearing portion <NUM> extending from the engagement portion <NUM>, and a threaded distal portion <NUM> extending from the bearing portion <NUM>. The proximal portion <NUM> of the power pin <NUM> has a diameter d. The engagement portion <NUM> as a diameter d1 smaller than diameter d of the proximal portion <NUM>. The bearing portion <NUM> has a diameter d2 smaller than diameter d1 of the engagement portion <NUM>. The threaded distal portion <NUM> has a diameter d3 smaller than diameter d2 of the bearing portion <NUM>.

The proximal portion <NUM> is configured to attach to the torch cable <NUM> (See <FIG>). A distal end <NUM> of the proximal portion <NUM> includes an annular face <NUM>, and a proximal end <NUM> includes an end face <NUM> with one or more fluid ports <NUM> which, in turn, are fluidly coupled to the central bore <NUM> via internal channels <NUM>. Air may be blown through the fluid ports <NUM> to blow out any fluids and clean the internal channels <NUM> and central bore <NUM>. Additionally, or alternatively, cooling fluid may flow through one or more of the internal channels <NUM> and the ports <NUM> to cool the torch <NUM>.

The end face <NUM> further includes a central bore inlet <NUM> configured to receive a cable adapter <NUM>. The bore inlet <NUM> has a larger diameter than the central bore <NUM>. The cable adapter <NUM> is a cylindrical tube that electrically and fluidly couples the power pin <NUM> and central bore <NUM> to a cable conductor <NUM>. That is, the cable adapter <NUM> is configured to receive arc process power (e.g., a weld current) and gas from the power pin <NUM>, and transfer the arc process power and gas to the cable conductor <NUM>. The liner <NUM> extends through the cable adapter <NUM> and cable conductor <NUM>. The adapter <NUM> further includes a seal <NUM> disposed between an inner surface 552A of the bore inlet <NUM> and an outer surface 554A of the cable adaptor <NUM> to prevent fluids from leaking through the bore inlet <NUM>.

The engagement portion <NUM> includes a distal end <NUM>, a proximal end <NUM>, an annular face <NUM> at the distal end <NUM>, and an outer surface <NUM>. The annular face <NUM> is angled with respect to the longitudinal axis <NUM> of the power pin <NUM>. That is, the annular face <NUM> is oblique to the longitudinal axis <NUM> and/or the outer surface <NUM> of the engagement portion <NUM> to soften the transition from the engagement portion <NUM> to the bearing portion <NUM> (e.g., to form a ramped surface).

The engagement portion <NUM> also includes an annular groove <NUM> that extends radially inward from the outer surface <NUM>. The annular groove <NUM> is fluidly coupled to the central bore <NUM> by one or more radial channels <NUM>. A process gas and/or shield gas may flow through the annular groove <NUM> and radial channels <NUM> to the central bore <NUM>. To prevent leakage, the annular groove <NUM> is bounded by a first annular seal seat 526A and a second annular seal seat 526B, each of which extend radially inward from the outer surface <NUM> and receive a seal <NUM>. That is, the first annular seal seat 526A is disposed between the distal end <NUM> of the engagement portion <NUM> and the annular groove <NUM> while the second annular seal seat 526B is disposed between the proximal end <NUM> of the engagement portion <NUM> and the annular groove <NUM>. Put still another way, the first annular seal seat 526A is disposed upstream from the annular groove <NUM> and the second annular seal seat is disposed downstream of the annular groove <NUM>.

The engagement portion <NUM> further includes one or more radial bores <NUM> with one or more engagement mechanisms <NUM> disposed therein (e.g., one mechanism <NUM> per bore <NUM>). Each engagement mechanism <NUM> is configured to engage an inner surface of the receiving block <NUM> of the socket <NUM> and provisionally hold the power pin <NUM> in place. That is, when the plug <NUM> is inserted into the socket <NUM>, the engagement mechanism <NUM> prevents the power pin <NUM> from sliding out of the receiving block <NUM>.

In the depicted embodiment, the engagement mechanism <NUM> comprises a ball <NUM> and spring <NUM> disposed in the radial bore <NUM>. The spring <NUM> is disposed radially inward of the ball <NUM> and exerts a radial outward force on the ball <NUM>. The radial outward force causes a portion of the ball <NUM> to extend past the outer surface <NUM> of the engagement portion <NUM> by a desired distance. The engagement mechanism <NUM> may further include a radial stop <NUM> to prevent the portion of the ball <NUM> from extending beyond the desired distance from the outer surface <NUM>, and/or completely exiting the radial bore <NUM>.

The ball <NUM> is capable of translating completely within the radial bore <NUM> if a radially inward force, greater than the radial outward force from the spring, is applied to the ball <NUM>. That is, a portion of the ball <NUM> extending past the outer surface <NUM> may be pushed into radial bore <NUM> such that a portion of the ball <NUM> does not radially extend beyond the outer surface <NUM>. However, forces applied in a direction perpendicular to the radial force from the spring (i.e., forces acting axially with respect to the power pin) may not cause the ball <NUM> to translate into the radial bore <NUM>. Thus, when the engagement mechanism <NUM> engages the receiving block <NUM>, the plug <NUM> may be prevented from translating along the longitudinal axis <NUM>.

That all said, embodiments are not limited to an engagement mechanism <NUM> having a ball <NUM> and spring <NUM> configuration. As an example, in some implementations, the engagement mechanism <NUM> may be a resilient member radially extending from the outer surface <NUM> of the engagement portion <NUM>. Specifically, the engagement mechanism <NUM> may include an annular protrusion extending from the outer surface <NUM>. As another example, the engagement mechanism may be a metal, a plastic, and/or a rubber ring disposed in a second annular groove in the outer surface <NUM>. As yet another example, the engagement portion <NUM> may include a second annular groove configured to receive an engagement mechanism disposed in the central bore <NUM> of the receiving block <NUM>.

While the engagement mechanism <NUM> is configured to engage the receiving block <NUM>, the bearing portion <NUM> of the power pin <NUM> is configured to be clamped by the receiving block <NUM>. The bearing portion <NUM> is dedicated to providing a large contact area, free of obstructions, for clamping by the receiving block <NUM>. The bearing portion <NUM> includes distal end <NUM>, a proximal end <NUM>, and a smooth outer surface or bearing surface <NUM> disposed therebetween. Said another way, the outer surface <NUM> does not include any surface protrusions or depressions. The smooth outer surface <NUM> provides consistent contact between the bearing portion <NUM> and an inner surface of the receiving block <NUM> in the clamped configuration C3. The consistent contact provides even clamping force along the bearing portion <NUM> and allows for efficient transmission of electricity between the receiving block <NUM> and power pin <NUM>; thus reducing power losses.

Still referring to <FIG> and <FIG>, the distal threaded portion <NUM> is configured to receive and secure the liner <NUM> with a liner cap <NUM>. The distal threaded portion <NUM> includes a first annular face a distal end <NUM>, a proximal end <NUM>, a threaded outer surface <NUM>, and a distal annular face <NUM> disposed at the distal end <NUM>. The central bore <NUM> extends through the distal annular face <NUM> and receives the liner <NUM>. The threaded liner cap <NUM> is disposed over a tip <NUM> of the liner <NUM> and the distal threaded portion <NUM>. The distal threaded portion <NUM>, the liner <NUM>, the liner cap <NUM> and liner tip <NUM> are concentrically arranged about longitudinal axis <NUM>. The distal threaded portion <NUM> and the liner cap <NUM> cooperate to hold the liner tip <NUM> and liner <NUM> in place.

Referring to <FIG>, the configuration of the liner <NUM>, the liner cap <NUM>, the liner tip <NUM>, and the distal threaded portion <NUM> of the power pin <NUM> is depicted. The liner cap <NUM> includes a top wall <NUM> having an annular face 611A and a circumferential sidewall <NUM> having an outer surface 612A and an inner surface 612B. The liner cap <NUM> further includes a chamfered surface <NUM> between the annular face 611A and the outer surface 612A. The chamfered surface <NUM> helps guide the power pin <NUM> into the central bore <NUM> of the receiving block <NUM>.

The liner cap <NUM> further includes a first cavity portion 614A and second cavity portion 614B. The inner surface 612B of the sidewall <NUM> defines the first cavity portion 614A, and inner surfaces 611B and 611C define the second cavity portion 614B. The first cavity portion 614A is configured to receive the distal threaded portion <NUM> of the power pin <NUM>. The inner surface 612B is threaded and configured to engage the threaded outer surface <NUM> of the threaded portion <NUM> of the power pin <NUM>. The second cavity portion 614B is configured to accommodate a portion of the liner tip <NUM> when the cap <NUM> is coupled to the threaded portion <NUM> and has a smaller diameter than a diameter of the first cavity portion 614A. Accordingly, a user may unscrew the cap <NUM> to access threaded portion <NUM>, the liner <NUM> and liner tip <NUM> for maintenance and/or to replace the liner <NUM> and liner tip <NUM>.

The liner cap <NUM> further includes a cap inlet <NUM> disposed in the top wall <NUM>. The cap inlet <NUM> has a frustoconical shape defined by a cap inlet surface 615A. The frustoconical cap inlet <NUM> transitions to an expanding outlet <NUM> defined by outlet surface 616A. The cap inlet <NUM> and outlet <NUM> are fluidly coupled to the second cavity portion 614B. That is, the cap inlet <NUM> and outlet <NUM> provide a passage through the top wall <NUM> to the second cavity portion 614B.

The liner tip <NUM> includes a distal end <NUM>, a proximal end <NUM>, and an elongate member, or ferrule, <NUM> extending from the distal end <NUM> to the proximal end <NUM>. The elongate member <NUM> includes an inner surface <NUM> that defines a channel <NUM> for receiving a portion of the liner <NUM>. The distal end <NUM> has a larger diameter than diameters of the elongate member <NUM> and of the central bore <NUM>. The difference in diameters between the distal end <NUM> and the elongate member <NUM> defines a first annular face <NUM>. The first annular face <NUM> is configured to abut the distal annular face <NUM> of the distal threaded portion <NUM>. Consequently, the distal end <NUM> of the tip <NUM> is prevented from passing through the bore <NUM>.

The distal end <NUM> further includes a second annular face <NUM> opposite the first annular face <NUM> and a tip inlet <NUM>. The tip inlet <NUM> has a frustoconical portion <NUM> defined by a tip inlet inner surface 6204A, and a bore portion <NUM> having substantially constant diameter defined by bore inner surface 6206A. The inlet <NUM> is fluidly coupled to the conduit <NUM> of the liner <NUM>.

When assembled, the liner <NUM> and tip elongate member <NUM> are inserted into the central bore <NUM> through the distal threaded portion <NUM> of the power pin <NUM>. The first annular face <NUM> of the distal end <NUM> of the liner tip <NUM> abuts the distal annular face <NUM> of the threaded portion <NUM> and prevents the liner tip <NUM> from passing completely through the bore <NUM>. The liner cap <NUM> cooperates with the distal threaded portion <NUM> of the power pin <NUM> to secure the liner <NUM> and liner tip <NUM> in place. That is, the liner cap <NUM> receives the threaded portion <NUM> in the first cavity portion 614A and receives the distal end <NUM> of the liner tip <NUM> in the second cavity portion 614B.

Meanwhile, the distal annular face <NUM> of the threaded portion <NUM> and the inner surfaces 611B and 611C of the second cavity portion 614B confine the distal end <NUM> of the liner tip <NUM>. For example, distal annular face <NUM> can bear against the first annular face <NUM> of the distal end <NUM>, and inner surface 611C of the cap <NUM> can bear against the second annular face <NUM>. The threaded inner surface 612B of cap sidewall <NUM> engages the outer threaded surface <NUM> to secure the liner cap <NUM> to threaded portion <NUM> of the power pin <NUM>. In other words, threads disposed on the inner surface 612B engage threads of the outer surface <NUM>. Consequently, the distal end <NUM> is restrained between the distal threaded portion <NUM> and the liner cap <NUM>, securing the liner tip <NUM> to the distal threaded portion <NUM>. Because the liner <NUM> is secured to an inner surface <NUM> of the elongate member <NUM> of the liner tip <NUM>, the liner <NUM> is also secured in place.

Now referring to <FIG>, the socket <NUM> and its receiving block <NUM> are depicted. The receiving block <NUM> includes a multi-diameter central bore <NUM> extending along a longitudinal axis <NUM> of the receiving block <NUM> that is configured to receive the multi-diameter power pin <NUM>. The receiving block <NUM> also includes receiver portion <NUM>, a dedicated clamping portion <NUM>, a distal portion <NUM>, and a quick release bolt <NUM> operatively coupled to the clamping portion <NUM>. Still further, the receiving block <NUM> includes a U-shaped coupler <NUM> extending from a bottom of receiver portion <NUM> and clamping portion <NUM> that is configured to receive the arc process power conductor <NUM>.

The multi-diameter central bore <NUM> extends through the receiver portion <NUM>, the clamping portion <NUM>, and the distal portion <NUM>. The central bore <NUM> has a diameter D1 through the receiver portion <NUM>, a variable diameter D2 through the clamping portion <NUM> and a diameter D3 through the distal portion <NUM>. D3 is less than diameter D1 while D2 is adjustable to a diameter that is also less than D1. Diameter D2 is varied by tightening of the quick release bolt <NUM> coupled to the clamping portion <NUM>. The arrangement between the quick release bolt <NUM> and clamping portion <NUM> are discussed below.

The receiver portion <NUM> includes a bore inlet 402A defining a lateral annular face 421A of the receiving block <NUM>. The bore inlet 402A has a frustoconical shape defined by a receiver inlet surface 421B. An inner surface 420A of the receiver portion <NUM> defines a receiver bore section 402B of the central bore <NUM> having a diameter D1. A first annular groove <NUM> (configured to receive the engagement mechanism <NUM> of the engagement portion <NUM>) and second annular groove <NUM> (configured to cooperate with the annular groove <NUM> of the engagement portion <NUM> to define a passageway for arc process gases) extend radially outward from the inner surface 420A. The first annular groove <NUM> has a curved surface 422A. A fluid channel <NUM> extends radially outward from the second annular groove <NUM> and ultimately to an external surface of the receiving block <NUM>. The fluid channel <NUM> fluidly couples the second annular groove <NUM> to a fluid supply of the feeder assembly <NUM>.

The receiving portion <NUM> further defines a frustoconical receiver outlet <NUM> of the receiver bore section 402B opposite the bore inlet 402A. The receiver outlet <NUM> is defined by an outlet surface 428A extending radially inwards and axially towards the clamping portion <NUM>. Said another way, a diameter of a section of the central bore <NUM> decreases along the receiver outlet <NUM> toward the clamping portion <NUM>.

The clamping portion <NUM> includes an inner surface 430A defining a clamping bore section 402C. The clamping portion <NUM> includes a first radial gap 432A, a second radial gap 432B parallel to the first radial gap 432A, and a third radial gap <NUM> extending from the first radial gap 432A to the second radial gap 432B. The first, second and third radial gaps 432A, 432B, and <NUM> extend radially from the clamping bore section 402C to one or more outer surfaces of the receiving block <NUM>. Additionally, the first, second, and third radial gaps 432A, 432B, and <NUM> define a resilient finger <NUM> having an upper portion 436A that receives a quick release bolt <NUM>.

The upper portion 436A can translate through the third radial gap <NUM> in response to a force received from the quick release bolt <NUM>. That is, a length of the third radial gap <NUM> can be varied in response to loosening or tightening of the quick release bolt <NUM>. For example, tightening the quick release bolt <NUM> decreases the length of the third radial gap <NUM> and the diameter D2 of the clamping bore section 402C. Conversely, loosening the quick release bolt <NUM> increases the length of the third radial gap <NUM> and increases the diameter D2 of the clamping bore section 402C. Consequently, the diameter D2 of the clamping bore section 402C is variable based on the force applied by the quick release bolt <NUM>.

In the depicted embodiment, the quick release bolt <NUM> is disposed in a laterally extending bore <NUM> that extends from an outer surface of upper portion 436A of the finger <NUM> and into the clamping portion <NUM> of the receiving block <NUM>. The quick release bolt <NUM> includes a handle <NUM> and a bolt <NUM>. The handle <NUM> includes a proximal end <NUM> and a distal end <NUM>. The proximal end <NUM> includes a cam <NUM>. The bolt <NUM> includes a proximal end <NUM> rotatably coupled to the proximal end <NUM> of the handle <NUM>, and a threaded distal end <NUM> for engaging threads of the lateral bore <NUM>. However, the quick release bolt <NUM> is merely an example of a tightening mechanism that may act on clamping portion <NUM> (and particularly on finger <NUM>) to lock a power pin <NUM> in the receiving block <NUM>.

Moreover, in the depicted embodiment, the quick release bolt <NUM> can be screwed into the lateral bore <NUM> with the handle <NUM> in a released position (e.g., configuration C2 shown in <FIG>). Additional force may be applied to the finger <NUM> by rotating the handle from the released position to the clamped position (e.g., configuration C3 shown in <FIG>). Rotating the handle <NUM> causes the cam <NUM> to apply additional force to the finger <NUM> and decrease the lateral length of the gap <NUM>. Accordingly, the finger <NUM> can translate in response to the handle <NUM> rotating from the clamped position to the released position and/or from the released position to the clamped portion. However, again, this tightening is merely an example and in other embodiments any tightening mechanism may be tightened in any manner now known or developed hereafter.

Still referring to <FIG>, the distal portion <NUM> of the receiving block <NUM> includes an inner surface 440A defining a distal bore section 402D having a diameter D3. The diameter D3 of the distal bore section 402D is less than the diameter D1 of the receiver bore section 402B. The distal bore section 402D is configured to receive the distal portion <NUM> of the power pin <NUM>.

Referring to <FIG>, the U-shaped coupler <NUM> extending from a bottom of receiver portion <NUM> and clamping portion <NUM> receives the arc process power conductor <NUM>. In the depicted embodiment, the coupler <NUM> includes a main body section <NUM> and a clamping section <NUM> having an inner surface <NUM> that defines a longitudinally extending receiving bore <NUM> configured to receive the conductor <NUM>. That is, the receiving bore <NUM> extends in a direction parallel to, and radially offset from, the longitudinal axis <NUM> of the receiving block <NUM> to receive the conductor <NUM>. However, in other embodiments, the coupler <NUM> might have a different shape or position that define the receiving bore <NUM> in a different configuration.

Moreover, in the depicted embodiment, a radial gap <NUM> between the main body section <NUM> and the clamping section <NUM> extends radially upward from the receiving bore <NUM>. A first through hole 465A extends laterally through the main body section <NUM>, and a second through hole 465B, coaxial with the firsts through hole 465A, extends laterally through the clamping section <NUM>. The first and second through holes 465A, 465B receive a clamping bolt <NUM>. The clamping bolt <NUM> applies a force to pull the clamping section <NUM> towards the main body section <NUM> until the inner surface <NUM> of the coupler <NUM> contacts and bears against an outer surface <NUM> of the conductor <NUM> thereby securing the conductor <NUM> within the receiving bore <NUM>. Accordingly, the conductor <NUM> is secured and electrically coupled to the coupler <NUM>, and thus, the receiving block <NUM>. However, again, this is merely an example and other embodiments may secure the conductor <NUM> to the coupler <NUM> in any desired manner.

Referring to <FIG>, a cross-sectional view of the connector <NUM> with the multi-diameter power pin <NUM> and the arc process power conductor <NUM> inserted into the receiving block <NUM> is shown. The connector <NUM> is shown in the third configuration C3 with power pin <NUM> clamped to the receiving block <NUM>. In this configuration, the engagement portion <NUM> is axially aligned with and accommodated within the receiving portion <NUM>, the bearing portion <NUM> is axially aligned with and accommodated within the clamping portion <NUM> and the threaded distal portion <NUM> is axially aligned with and accommodated within the distal portion <NUM>. To accommodate the portions of the power pin <NUM> with the portions of the receiving block <NUM>, the diameter D1 of the receiver bore section 420B (see <FIG>) is slightly larger than the diameter d1 of the engagement portion <NUM> (See <FIG>). Similarly, the variable diameter D2 of the clamping bore section 402C and diameter D3 of the distal portion <NUM> is slightly larger than diameter d2 of the bearing portion <NUM> and diameter d3 of the distal threaded portion <NUM>, respectively (see <FIG> and <FIG>).

Still referring to <FIG>, the receiver portion <NUM> abuts the proximal portion <NUM> of the power pin <NUM> to axially align each portion of the power pin <NUM> with each corresponding portion of the receiving block <NUM>. That is, the annular face <NUM> of the proximal portion <NUM> faces and abuts the lateral annular face 421A of the receiver portion <NUM>. With the power pin <NUM> aligned with the receiving block <NUM>, the second annular groove <NUM> of the portion <NUM> cooperates with the annular groove <NUM> of the engagement portion <NUM> to form an annular fluid channel <NUM>. Additionally, the engagement mechanism <NUM> engages the first annular groove <NUM> of the receiver portion <NUM> to provisionally hold the power pin <NUM> in the central bore <NUM>.

For example, the spring <NUM> of the engagement mechanism <NUM> pushes a portion of the ball <NUM> into the first annular groove <NUM>. The ball <NUM> and first annular groove <NUM> prevent axial movement of the power pin <NUM>, unless a radial force sufficient to overcome the force from the spring <NUM> is applied to the ball <NUM>. An axial force may be transferred through the power pin <NUM> to the ball <NUM> which bears against a portion of the first annular groove <NUM>. A portion of the axial force can be converted into a radial force in response to the ball <NUM> bearing against the curved surface 422A of the first annular groove <NUM>. Therefore, if the connector <NUM> is moved out of its third configuration C3 (e.g., to configuration C2) a user can disengage the engagement mechanism <NUM> by pulling with sufficient axial force such that the curved surface 422A converts the axial force into a radial force greater than the spring force.

As mentioned, embodiments are not limited to one engagement mechanism <NUM> having a ball <NUM> and spring <NUM> arrangement. In some implementations the engagement portion <NUM> may include a plurality of engagement mechanisms <NUM>. For example, the engagement portion <NUM> may include two, three, four, or more engagement mechanisms <NUM> to engage the first annular groove <NUM> of the receiver portion <NUM>. In some implementations, the engagement mechanism <NUM> may be a resilient annular ring that protrudes from or is disposed on the engagement portion <NUM>. For example, the engagement mechanism may be a plastic, metal, and/or rubber ring secured to the engagement portion <NUM>. Alternatively, the engagement mechanism <NUM> may be a protrusion extending from the outer surface <NUM> of the engagement portion <NUM>. Alternatively, one or more engagement mechanisms <NUM> may be disposed in the receiver portion <NUM> and the first annular groove <NUM> may be disposed at the engagement portion <NUM>.

In addition to receiving the engagement mechanism <NUM>, the receiver portion <NUM> fluidly couples the feeder <NUM> to the torch cable <NUM> via the engagement portion <NUM>. For example, fluid channel <NUM>, the annular fluid channel <NUM> (e.g., annular grooves <NUM> and <NUM>), the internal channels <NUM>, the pin central bore <NUM>, and the cable conductor <NUM> form a fluid passageway from the wire feeder assembly <NUM> to the torch <NUM>. The seals <NUM> disposed in the first and second annular seal seats 526A, 526B of the engagement portion <NUM> prevent leakage of the process gas from the annular fluid channel <NUM>. An additional sealing means of the receiving portion <NUM> is provided by the annular face <NUM> butting the outlet surface 428A and the annular face <NUM> abutting the lateral annular face 421A. Accordingly, process gas flowing through the fluid channel <NUM> is prevented from leaking out of the receiver bore section 402B (see <FIG>) and past the receiver portion <NUM>. To further protect the connector <NUM> from fluid leaks, seals <NUM> prevent the process gas from leaking past the cable adapter <NUM>, and seals <NUM> and <NUM> prevent process gas from leaking past the liner cap <NUM> and liner tip <NUM>, respectively. The seals <NUM>, <NUM>, <NUM>, <NUM> may be O-rings.

Still referring to <FIG>, once the engagement portion <NUM> engaged and fluidly coupled to the receiver portion <NUM>, a user may clamp the clamping portion <NUM> to the bearing portion <NUM> using the quick release bolt <NUM> (see <FIG>) to place the connector <NUM> into its clamped configuration C3. This presses the finger <NUM> into gap <NUM> until the inner surface 430A presses or bears against the bearing surface <NUM> of the bearing portion <NUM>. As discussed above, the bearing surface <NUM> does not include any surface features that obstructs contact of the inner surface 430A to the bearing surface <NUM>. Therefore, the finger <NUM> can effectively clamp the bearing portion <NUM> in place, and secure the plug <NUM> in the socket <NUM>. Moreover, the contact between the inner surface 430A and the bearing surface <NUM> electrically couples the receiving block <NUM> to the power pin <NUM>.

During operation, power from the conductor <NUM> is conducted through the receiving block <NUM> to the power pin <NUM> and then conducted through the cable adapter <NUM> to the cable conductor <NUM>. For example, an electric current is conducted from the conductor <NUM> to the U-shaped coupler <NUM>, through the receiving block <NUM> where the electricity is conducted from inner surface 430A to the bearing surface <NUM> of bearing portion <NUM>. The current is then conducted through the cable adapter <NUM> and the cable conductor <NUM> to the torch <NUM>. Additionally, process gas flows from the wire feeder assembly <NUM> through fluid channel <NUM> into the annular fluid channel <NUM>. The process gas then passes through pin internal channels <NUM>, the pin central bore <NUM>, the cable adapter <NUM>, and the cable conductor <NUM> to the torch <NUM>.

In addition to power and process gas, a weld wire is guided through the power pin <NUM> and torch cable <NUM> to the torch <NUM>. As discussed above, weld wire is pulled from a wire supply <NUM> by wire rollers <NUM> and is isolated from electrical currents and process gases by the liner <NUM>. A wire guide <NUM>, supported in the feeder assembly <NUM> by a guide support <NUM>, receives the weld wire from the wire rollers <NUM> and guides the weld wire to the multi-diameter central bore <NUM>. The distal threaded portion <NUM> with liner cap <NUM> and the cap inlet <NUM> are radially aligned with the wire guide <NUM>. The weld wire enters the cap <NUM> via the cap inlet <NUM>. The cap inlet surface 615A guides the weld wire radially inwards and towards the liner tip inlet <NUM>. The tip inlet inner surface 6204A guides the weld wire radially inwards and towards the liner conduit <NUM>. Both the cap inlet surface 615A and the tip inlet inner surface 6204A prevent kinking and/or jamming of the weld wire after it exits the wire guide <NUM>. The liner <NUM> (which extends through the torch cable <NUM> to the torch <NUM>) guides the weld wire to the torch <NUM> where it is consumed in an arc welding process. The liner <NUM>, liner cap <NUM>, and liner tip <NUM> isolate weld wire received in the conduit <NUM> from gas flowing through the power pin <NUM> and from contacting the inner surface of the power pin <NUM> defining the central bore <NUM>.

Now Referring to <FIG>, a receiving block <NUM> according to a second embodiment is shown. The receiving block <NUM> is similar to receiving block <NUM>, except the clamping bolt <NUM> for clamping the conductor <NUM> is replaced with a quick release bolt <NUM> similar to quick release bolt <NUM>. The configuration of receiving block's clamping portion and U-shaped conductor connector are adjusted to accommodate the quick release bolt <NUM>. For brevity, only the differences between receiving block <NUM> and receiving block <NUM> are discussed.

As shown in <FIG>, the receiving block <NUM> includes a receiver portion <NUM>, a clamping portion <NUM>, a distal portion <NUM>, and a U-shaped conductor coupler <NUM>. As shown in <FIG>, the U-shaped conductor coupler <NUM> includes a main body section <NUM> that extends from a bottom of the receiving block <NUM> downwardly at an angle with respect to a vertical axis <NUM>. A clamping portion <NUM> extends upwards from the main body section <NUM> to define a longitudinally extending receiving bore <NUM>.

A first through hole 1465A extends laterally through the main body section <NUM>, and a second through hole 1465B, coaxial with the firsts through hole 1465A, extends laterally through the clamping section <NUM>. The first and second through holes 465A, 465B receive a quick release bolt <NUM>. To accommodate the quick release bolt <NUM>, the first and second through holes 465A, 465B extend at an oblique angle with respect to the vertical axis <NUM>. When clamped, the quick release bolt <NUM> applies a force to pull the clamping section <NUM> towards the main body section <NUM> until an inner surface <NUM> of the coupler <NUM> contacts and bears against an outer surface <NUM> of the conductor <NUM> thereby securing the conductor <NUM> within the receiving bore <NUM>. Accordingly, the conductor <NUM> is secured and electrically coupled to the U-shaped conductor coupler <NUM>, and thus, the receiving block <NUM>.

In the depicted embodiment, the clamping portion <NUM> includes an inner surface 1430A for engaging the power pin <NUM>. The clamping portion <NUM> includes a first radial gap 1432A, a second radial gap 1432B parallel to the first radial gap 1432A. The first and second radial gaps 1432A, 1432B extend perpendicularly with respect to the vertical axis <NUM>. A third radial gap <NUM> extends from the first radial gap 1432A to the second radial gap 1432B. The first, second and third radial gaps 1432A, 1432B, and <NUM> extend radially from the inner surface 1430A to one or more outer surfaces of the receiving block <NUM>. Additionally, the first, second, and third radial gaps 1432A, 1432B, and <NUM> define a resilient finger <NUM> having a lateral portion 1436A that receives a quick release bolt <NUM>. The resilient finger <NUM> extends in a direction substantially perpendicular to the vertical axis <NUM>.

As shown in <FIG>, the quick release bolt <NUM> is disposed in a vertically extending bore <NUM> that extends from an outer surface of the lateral portion 1436A of the finger <NUM> and into the clamping portion <NUM> of the receiving block <NUM>. The upper portion 1436A can translate through the third radial gap <NUM> in response to a force received from the quick release bolt <NUM>. That is, a length of the third radial gap <NUM> can be varied in response to loosening or tightening of the quick release bolt <NUM>. For example, tightening the quick release bolt <NUM> decreases the length of the third radial gap <NUM>. Conversely, loosening the quick release bolt <NUM> increases the length of the third radial gap <NUM>. Consequently, the length of the third radial gap <NUM> is variable based on the force applied by the quick release bolt <NUM>. Thus, the quick release bolt <NUM> can be tightened and loosened to place the clamping portion <NUM> between a clamped position (e.g., similar to configuration to C3 shown in <FIG>) and a released position (e.g., similar to configuration C2 shown in <FIG>).

Accordingly, a connector <NUM> is presented in which the liner cap <NUM> and liner <NUM> can be easily installed, secured, and/or replaced without the drawbacks of the conventional liner and bolt arrangement noted above. Additionally, with one hand, a user can insert the power pin <NUM> into a receiving block <NUM>, <NUM> and provisionally lock the plug <NUM> with the engagement mechanism <NUM>, let go of the torch cable <NUM>, and clamp and secure the power pin <NUM> in place with the quick release bolt <NUM>. Consequently, electricity and fluid may be efficiently transmitted from the receiving block <NUM>, <NUM> to the power pin <NUM> without the drawbacks of the conventional power pin noted above.

While the invention has been illustrated and described in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the present invention as defined in the appended claims.

It is also to be understood that the welding system <NUM> described herein, or portions thereof may be fabricated from any suitable material or combination of materials, such as plastic, foamed plastic, wood, cardboard, pressed paper, metal, supple natural or synthetic materials including, but not limited to, cotton, elastomers, polyester, plastic, rubber, derivatives thereof, and combinations thereof. Suitable plastics may include high-density polyethylene (HDPE), low-density polyethylene (LDPE), polystyrene, acrylonitrile butadiene styrene (ABS), polycarbonate, polyethylene terephthalate (PET), polypropylene, ethylene-vinyl acetate (EVA), or the like. Suitable foamed plastics may include expanded or extruded polystyrene, expanded or extruded polypropylene, EVA foam, derivatives thereof, and combinations thereof.

Claim 1:
A multi-diameter power pin (<NUM>) for a plug (<NUM>) of a cable (<NUM>) for an arc process system, the power pin (<NUM>) comprising:
a proximal portion (<NUM>) having a first diameter (d), the proximal portion (<NUM>) disposable at a proximal end (<NUM>) of the plug (<NUM>), the proximal portion (<NUM>) electrically couplable to the cable (<NUM>);
an engagement portion (<NUM>) extending from the proximal portion (<NUM>), the engagement portion (<NUM>) having a second diameter (d1) smaller than the first diameter (d);
the pin being characterised by the following:
bearing portion (<NUM>) extending from the engagement portion (<NUM>), the bearing portion (<NUM>) having a third diameter (d2) smaller than the second diameter (d1); and
a distal threaded portion (<NUM>) comprising a first annular face with a distal end (<NUM>), a proximal end (<NUM>), a threaded outer surface (<NUM>), and a distal annular face (<NUM>) disposed at the distal end (<NUM>), the distal thread portion (<NUM>) having a fourth diameter (d3) smaller than the third diameter (d2).