A yarn tensioner is designed for adjusting tension in a running yarn. The yarn tensioner includes a rotatable tension wheel having opposing yarn-contacting surfaces formed along an annular region thereof and configured to frictionally contact opposite sides of the running yarn such that the running yarn causes rotational movement of the tension wheel. An elongated wheel shaft is directly affixed to the tension wheel. A tension adjustment assembly frictionally contacts the wheel shaft, and creates select rotation resistance between adjacent parts of the assembly and the wheel shaft such that rotation of the tension wheel is adjustably frictionally controlled, thereby adjusting tension in the running yarn.

A wire feeder includes a tensioner with a discrete number of compressive force settings for applying a desired compressive force to welding wire fed through the wire feeder is provided. The tensioner includes an adjustment knob with a discrete number of detents disposed along a helical surface adjacent an inner bore of the adjustment knob. The tensioner also includes a pin extending from an end of a tensioning post located in the inner bore, the pin being configured to align with the detents of the adjustment knob. Rotation of the adjustment knob adjusts alignment of the pin among the discrete number of detents, which correspond to the discrete number of compressive force settings.

A yarn tensioner is designed for adjusting tension in a running yarn. The yarn tensioner includes a rotatable tension wheel having opposing yarn-contacting surfaces formed along an annular region thereof and configured to frictionally contact opposite sides of the running yarn such that the running yarn causes rotational movement of the tension wheel. An elongated wheel shaft is directly affixed to the tension wheel. A tension adjustment assembly frictionally contacts the wheel shaft, and creates select rotation resistance between adjacent parts of the assembly and the wheel shaft such that rotation of the tension wheel is adjustably frictionally controlled, thereby adjusting tension in the running yarn.

A wire feeder includes a tensioner with a discrete number of compressive force settings for applying a desired compressive force to welding wire fed through the wire feeder is provided. The tensioner includes an adjustment knob with a discrete number of detents disposed along a helical surface adjacent an inner bore of the adjustment knob. The tensioner also includes a pin extending from an end of a tensioning post located in the inner bore, the pin being configured to align with the detents of the adjustment knob. Rotation of the adjustment knob adjusts alignment of the pin among the discrete number of detents, which correspond to the discrete number of compressive force settings.

A wire feeder includes a tensioner with a discrete number of compressive force settings for applying a desired compressive force to welding wire fed through the wire feeder is provided. The tensioner includes an adjustment knob with a discrete number of detents disposed along a helical surface adjacent an inner bore of the adjustment knob. The tensioner also includes a pin extending from an end of a tensioning post located in the inner bore, the pin being configured to align with the detents of the adjustment knob. Rotation of the adjustment knob adjusts alignment of the pin among the discrete number of detents, which correspond to the discrete number of compressive force settings.