A system for controlling multiple wire feed motors for use in a welding-type system including a push motor controlled to operate at a target wire feed speed and a pull motor disposed in a welding torch controlled to apply a target torque to the fed welding wire. Such a system eliminates shaving and bird nesting of welding wire.

A device for feeding a wire electrode includes a housing having an input port, an output port, and a cavity defined by the housing. The device also includes a first group of bearings and a second group of bearings disposed within the housing. Each of the bearings have a surface configured to engage and drive the wire electrode. Additionally, each of the bearings have teeth adjacent to the perimeter of the bearings. The teeth of the bearings forming the first group are in meshing engagement with each other, while the teeth of the bearings forming the second group are in meshing engagement with each other. The device also includes a drive sprocket within the housing and having teeth that mesh with the teeth of one of the bearings of the first group and the teeth of one of the bearings of the second group.

A device for feeding a wire electrode includes a housing having an input port, an output port, and a cavity defined by the housing. The device also includes a first group of bearings and a second group of bearings disposed within the housing. Each of the bearings have a surface configured to engage and drive the wire electrode. Additionally, each of the bearings have teeth adjacent to the perimeter of the bearings. The teeth of the bearings forming the first group are in meshing engagement with each other, while the teeth of the bearings forming the second group are in meshing engagement with each other. The device also includes a drive sprocket within the housing and having teeth that mesh with the teeth of one of the bearings of the first group and the teeth of one of the bearings of the second group.

An apparatus and system for preheating and removing surface oxidation of welding wire using electric arcs one via one or more tungsten electrodes is disclosed. The preheating and cleaning electric arcs may occur between tungsten electrodes, or between one or more tungsten electrodes and welding wire. Electric arc preheating of welding wire allows increased efficiency and deposition rates.

An apparatus and system for preheating and removing surface oxidation of welding wire using electric arcs one via one or more tungsten electrodes is disclosed. The preheating and cleaning electric arcs may occur between tungsten electrodes, or between one or more tungsten electrodes and welding wire. Electric arc preheating of welding wire allows increased efficiency and deposition rates.

Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

Provided is an articulated welding robot that includes an articulated arm in which a plurality of arm parts are linked via a drive shaft. A welding wire is disposed along the articulated arm. In at least one of the arm parts a depression is formed that forms a hollow on the inner side of the arm. At least a portion of the welding wire is accommodated in the depression.

A system and method for controlling the position of a filler wire and/or a laser head, or other heating head, in a welding system. The distal end of the filler wire is gradually moved, e.g., upward, until electrical continuity with the weld pool is lost; the filler wire is then moved back into contact with the weld pool. The heating head may be stationary relative to the weld pool, or it may move, with the distal end of the filler wire, relative to the weld pool.

A processing head assembly is disclosed. In some examples, the processing head assembly comprises a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles. In some examples, the fabrication energy source includes the wire feedstock surrounded by the shield. A method of depositing material on a substrate using a processing head assembly for use with a fabrication energy source; a wire feedstock surrounded by a shield and one or more filler feedstocks surrounded by one or more nozzles is disclosed. In some examples, the method comprises projecting a fabrication energy beam from the fabrication energy source onto the substrate at a spot, projecting the wire feedstock surrounded by the shield onto the substrate at the spot and projecting the one or more filler feedstocks surrounded by the one or more nozzles onto the substrate close to the spot.