Rotary power connector for a welding torch cable

Abstract

A rotary power connection for connecting a power supply cable to a welding torch body is provided. In the rotary power connection, mechanical loads are carried by steel bearings, and electrical loads are carried by multi-contact spring-loaded fins made of a high-conductive material or coating. In some examples, the rotary power connector is attached to the welding torch prior to power connection to the wire feeder. The rotary power connector advantageously allows rotation of the welding torch relative to the single cable while providing a continuous electrical connection at high current levels used in welding applications.

Description

[0001] Cross-references to related applications

[0002] This application hereby claims priority and benefit to U.S. Provisional Application Serial No. 63 / 077,353, filed September 11, 2020, entitled “ROTATING POWER CONNECTORFOR WELDING TORCH CABLES”. U.S. Provisional Application Serial No. 63 / 077,353 is incorporated herein by reference in its entirety for all purposes. Background Technology

[0003] In arc welding, it is known to use power cables to conduct current, shielding gas, and electrode wire through the welding torch. The power cable, often referred to as the single cable of an air-cooled welding torch, generally consists of a core tube, copper wire, leads, and an insulating sheath. Typically, this cable is connected to other torch components via crimping or threaded fitting. One end of the cable is secured to the wire feeder by a mating pin (or power pin), and the other end is fixed to the torch body via the torch's gooseneck or conductor tube. These connections are stationary.

[0004] Power cables provide welding torches with great flexibility, allowing welding arcs to be applied from various locations. However, conventional fixed connections restrict the torsional movement of the copper bundle within a single cable, creating stress concentrations that can ultimately lead to failure of the torch's electrical connections. Conventional cables are mounted in a fixed position and twist as the torch rotates during user or robot manipulation. This is problematic in some robot designs, as the cable can suffer severe mechanical wear, leading to failure of the fixed cable connection or the entire cable. In the case of coaxially mounted torches, any rotation of the robot's axis, coaxial with the cable, applies a rotational torque to the cable. When the cable twists at a bend in the profile, torsional strain / stress concentrates at one end, causing mechanical failure of the cable. Summary of the Invention

[0005] This disclosure provides a rotary power connector that can be fixed to a welding torch, such as between the torch body and a single cable or after the handle. This disclosure advantageously allows rotation of the torch body relative to the single cable without disrupting electrical contact or imposing unnecessary strain on the single cable. For example, when the torch is mounted on a robotic arm, the rotary power connector allows the torch body to rotate about the robot's axis of rotation, while the single cable does not, thereby eliminating any torque in the single cable and reducing mechanical wear on it.

[0006] These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken in conjunction with the accompanying drawings. Attached Figure Description

[0007] These and other features, aspects, and advantages of this disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, throughout which the same reference numerals denote the same parts:

[0008] Figure 1 An example robotic welding system is shown, based on various aspects of this disclosure.

[0009] Figure 2A and Figure 2B A cross-sectional view of an example rotating electrical connector is shown, representing various aspects of this disclosure.

[0010] Figure 2C This disclosure demonstrates various aspects of the content. Figure 2A A 3D view of an example rotating power connector.

[0011] Figures 3A to 3E This disclosure demonstrates various aspects of the content. Figure 2A A 3D view of an example rotating power connector.

[0012] Figure 4 A cross-sectional view of an example rotating electrical connector is shown, representing various aspects of this disclosure.

[0013] Figure 5 This disclosure demonstrates various aspects of the content. Figure 4 A 3D view of an example rotating power connector.

[0014] The accompanying drawings are not necessarily drawn to scale. Where appropriate, similar or identical reference numerals are used to refer to similar or identical parts. Detailed Implementation

[0015] This disclosure generally relates to electric welding, and more specifically, to a rotary power connector for connecting a power cable to the body of a welding torch. In particular, a rotary power connector is disclosed that can be attached to the torch from behind a gooseneck or the torch body. The disclosed rotary power connector advantageously allows rotation of the torch relative to a single cable while providing a continuous electrical connection at the high current levels used in welding applications.

[0016] In some examples, the welding torch is mounted on the robotic arm of the robotic welding system, and the rotary power connector allows the torch body to rotate about the axis of rotation of the robotic arm without twisting the single cable, thereby reducing the torque of rotation on the single cable and reducing mechanical wear on the single cable.

[0017] In some examples, the rotary power connector includes a generally cylindrical housing having a longitudinal axis. A connector pin is arranged within the housing and extends from a first end of the housing. A rotary stud is rotatably arranged within the housing and extends from a second end of the housing opposite to the first end.

[0018] Some ends of the connector pin and the rotating stud are in contact within the housing. One or more electrical contact rings are arranged within the housing. The electrical contact rings include at least one contact extension that is deflected, for example, by a spring force, to contact the rotating stud. For example, each contact extension may include one or more layers, each layer having a plurality of fins disposed around the rotating stud.

[0019] As disclosed herein, the electrical contact ring provides a more robust form of electrical contact, resulting in a more stable bond for welding. Consequently, less heat is generated at the interface. The needle arc does not protrude as much as before, leading to premature failure.

[0020] Furthermore, in some examples, the rotary power connector includes one or more bearings, such as needle roller bearings, around the rotating stud to provide mechanical stability and free rotation of the stud. The bearings provide greater alignment and / or resistance to lateral loads (e.g., deviations from the axial direction) that could affect the proper operation of the entire robot system, thereby extending the component's lifespan. Smoother, freer rotation of the component enables reliable operation and a longer lifespan for single-cable assemblies.

[0021] Advantageously, the disclosed rotary power connector provides stable electrical contact between the rotating component and the connector pin, while the bearing provides mechanical support and smooth rotation, thereby reducing strain on the attached single cable. Additionally, the dimensions of the rotary power connector and its components are determined for assembly into existing welding system housings, robotic arms, etc., thereby enabling seamless exchange between existing rotary power connectors and / or rotary power connectors as disclosed herein.

[0022] In the disclosed example, a rotary power connector for a welding torch includes: a housing having a longitudinal axis; a connector pin disposed within the housing and extending from a first end of the housing; a stud disposed within the housing and extending from a second end of the housing; and one or more electrical contact rings disposed within the housing and surrounding one or more of the connector pin or the stud, the one or more electrical contact rings including one or more contact extensions that offset toward an outer surface of the connector pin or the stud during rotation of the rotary power connector relative to a single cable to provide electrical contact between the one or more contact extensions and the outer surface.

[0023] In some examples, the connector pin is configured to insert into the welding torch to connect the rotary power connector to the welding torch, the connector pin rotating relative to the one or more contact rings. In some examples, the stud may be connected to the single cable and is configured to rotate relative to the one or more contact rings. In some examples, each of the connector pin and the stud includes a central channel for delivering one or more of the shielding gas or welding wire.

[0024] In the example, the inner housing is disposed within the outer housing and generally surrounds the one or more contact rings. In some examples, the inner housing contacts the connector pin or the one or more contact rings to provide a current path for allowing current to flow from the stud through the contact rings or the inner housing into the connector pin.

[0025] In some examples, a bearing is arranged around the stud, which facilitates rotation of the connector pin or the stud relative to the inner housing. In one example, the bearing comprises a needle roller bearing arranged between one of the one or more contact rings and a first or second end of the housing.

[0026] In some examples, the one or more contact extensions include a plurality of spring-loaded, highly conductive fins. In some examples, each of the plurality of fins is fixed at a first end to a corresponding contact ring and offset at a second end or in a portion between the first and second ends to cause the fin to move inward to engage the outer surface.

[0027] In the disclosed example, an assembly for the rotational movement of a single welding torch cable includes: a connector that rotatably connects the single welding torch cable to a welding torch body such that the single cable is rotatable relative to the welding torch body. The connector includes: a cylindrical housing having a longitudinal axis; a connector pin fixedly and axially disposed within the housing and extending from a first end of the housing; a rotating stud disposed within the housing and extending from a second end of the housing opposite to the first end; an inner housing located within the housing, wherein the connector pin is in electrical contact with the inner housing; and one or more contact rings disposed within and in electrical contact with the inner housing, each of the one or more contact rings including at least one contact extension that is offset during the rotational movement of the rotating stud to contact the rotating stud.

[0028] In some examples, each of the single cable, the swivel stud, and the connector includes a passage along the same axis for transmitting welding wire or shielding gas to the welding torch. In some examples, the swivel stud of the connector may be connected to the single cable.

[0029] In the disclosed example, a rotary power connector for a welding torch includes: a housing having a longitudinal axis; a connector pin disposed within the housing and extending from a first end of the housing; a stud disposed within the housing and extending from a second end of the housing; and one or more contact extensions disposed within the housing and surrounding one or more of the connector pin or the stud, the one or more contact extensions being offset toward an inner surface of the inner housing to provide electrical contact between the one or more contact extensions and the inner surface during rotation of the rotary power connector relative to a single cable.

[0030] In some examples, the one or more contact extensions include a plurality of fins, each fin having a first end and a second end. In one example, each of the plurality of fins is secured at the first end to the outer surface of the connector pin or the stud, and is offset at the second end to push the fin outward to engage with the inner surface.

[0031] In some examples, the connector pin is configured to insert into a welding torch to connect the rotary power connector to the torch, the connector pin rotating relative to the inner housing. In another example, the stud may be connected to the single cable and is configured to rotate relative to the inner housing.

[0032] In some examples, bearings are arranged around the stud or contactor pin, which facilitate rotation of the connector pin or stud relative to the inner housing. In one example, the bearing includes a needle roller bearing arranged between one or more contact extensions and a first or second end of the housing.

[0033] As used herein, the terms “first” and “second” can be used to enumerate different parts or elements of the same type and do not necessarily imply any particular order.

[0034] As used herein, the term "welding system" includes any device capable of supplying power for welding, plasma cutting, induction heating, carbon arc air cutting (e.g., CAC-A) and / or hot wire welding / preheating (including laser welding and laser cladding), including inverters, converters, choppers, resonant power supplies, quasi-resonant power supplies, etc., and associated control circuitry and other auxiliary circuitry.

[0035] As used herein, the term "welding power" refers to power suitable for welding, plasma cutting, induction heating, CAC-A and / or hot wire welding / preheating (including laser welding and laser cladding). As used herein, the terms "welding power supply" and / or "power supply" refer to any device capable of supplying power to welding, plasma cutting, induction heating, CAC-A and / or hot wire welding / preheating (including laser welding and laser cladding) when power is applied thereto, including but not limited to inverters, converters, resonant power supplies, quasi-resonant power supplies, etc., and their associated control circuitry and other auxiliary circuitry.

[0036] As used herein, the terms “torch,” “welding torch,” “welding tool,” or “welding instrument” refer to a device configured to be manipulated to perform welding-related tasks and may include handheld welding torches, robotic welding torches, welding guns, planing tools, cutting tools, or other devices for generating a welding arc.

[0037] As used herein, the terms “welding mode,” “welding process,” “welding type process,” or “welding operation” refer to the type of process or output used, such as current-controlled (CC), voltage-controlled (CV), pulse-controlled gas metal arc welding (GMAW), flux-cored wire arc welding (FCAW), gas tungsten inert gas welding (GTAW, e.g., TIG), metal shielded arc welding (SMAW), spatter, short circuit, CAC-A, planing process, cutting process, and / or any other type of welding process.

[0038] As used herein, the term "welding program" or "weld program" includes at least one set of welding parameters for controlling welding. A welding program may further include other software, algorithms, processes, or other logic for controlling one or more welding devices to perform welding.

[0039] Now turn to the attached diagram, Figure 1A perspective view of an example robotic welding system using a rotary power connector is provided. The welding torch 10 (e.g., a gas shielded metal arc welding (GMAW) torch, a metal inert gas (MIG) torch, etc.) includes: a torch body having a main housing 12, a gooseneck 14, and a contact end or nozzle assembly 16; a power cable, such as a single cable assembly 18; and a power pin (not shown) cooperating with a wire feeder 20. Shielding gas, current, and consuming electrodes (e.g., welding wire) are guided through the torch 10 to output a welding arc at the nozzle assembly 16. In some examples, the rotary power connector is arranged within the main housing 12, thereby providing a conductive assembly between the single cable assembly 18 and the main housing 12.

[0040] The single-cable assembly 18 may include one or more of a core tube, copper cable, or protective lead (a non-limiting list by way of example). The single-cable 18 may be connected to a wire feeder 20 located on the opposite side of the main housing 12 of the welding torch 10. A gooseneck tube 14 is operatively connected to the front end of the main housing 12 and facilitates the delivery of the consuming electrode, shielding gas, and / or welding current to a nozzle assembly 16 mounted on the gooseneck tube. The welding torch 10 is coaxially mounted to the robotic arm 22 such that the single-cable 18 is arranged along the central axis of the robotic arm 22. However, the welding torch 10 may be mounted to the robotic arm in a different configuration than the coaxial mounting. In some examples, the robotic arm 22 is configured to rotate the welding torch 10 generally about the central axis of the robotic arm 22 in direction 11 and in direction 13. For example, a motor or other actuator 23 may be used to control the movement of the welding torch 10 via the main housing 12 in one or more directions 13.

[0041] The wire feeder 20 feeds the welding wire through the single cable 18, the main housing 12, the gooseneck tube 14, and finally through an opening in the contact end / nozzle assembly 16 at the tip of the welding torch 10. The welding wire is at a high potential when energized for welding. As the welding wire forms an arc with the metal workpiece, the circuit is completed, and current flows through the welding wire, across the arc to the metal workpiece, and to ground or other types of current loops. The arc melts the metal of both the welding wire and the workpiece, thus bonding them together with the workpiece as the melt solidifies.

[0042] Figure 2 illustrates an example rotary power connector 26. As shown, a rotary stud 40 is configured to mate with the end of a single cable 18, thereby providing a connection to the rotary power connector 26. The single cable 18 can be removably or permanently secured to the rotary power connector 26 by one or more fasteners, such as threaded portions 51, locking screws, and / or retaining screws (as a list of non-limiting examples)

[0043] The rotary power connector 26 includes a generally cylindrical housing 30 having a longitudinal axis 32. A connector pin 34 is removably or fixedly disposed within the housing 30, aligned with the axis 32, and extends from the end of the rotary power connector 26 opposite to the rotary stud 40. The connector pin 34 may be generally tubular, having a flange portion 38 for securing the connector pin to the housing 30. A rotating member, such as the rotary stud 40, is rotatably disposed within the housing 30, aligned with the axis 32. The rotary stud 40 is also generally tubular, having a flange portion 46 at its end. The opposite end portion 48 of the rotary stud 40 is disposed outside the housing 30 and can be inserted into and connected to the end of a single cable 18. One or more washers, O-rings 49, or similar seals are disposed at the end of the housing 30 from which the rotary stud 40 or connector pin 34 extends.

[0044] An inner housing 50 is disposed within an outer housing 30. The inner housing 50 generally extends from one end of the outer housing to the other and extends to overlap the interface between the connector pin 34 and the swivel stud 40. The inner housing 50 generally surrounds the swivel stud 40 and supports the connector pin 34 and the swivel stud. One or more electrical contact rings 52, 53 are disposed within the outer housing 30 and between the inner housing 50 and the swivel stud 40. In this example, each contact ring 52, 53 surrounds the swivel stud 40 and includes at least one contact extension 54, 55 that contacts the swivel stud 40.

[0045] For example, as in the example Figures 3A to 3E As shown, the contact ring 52 may include multiple contact extensions 54, such as one or more layers and / or spring-loaded highly conductive fins 99. In some examples, each layer may include multiple fins surrounding the rotating stud 40, but the rotary power connector 26 is not limited to any specific number of contact extensions / fins / support layers. In some examples, the contact extensions 54 may be secured to the contact ring 52 at a first end 101 and offset at a second end 102 to contact the surface 41 of the rotating stud 40. Figure 3C In some of the examples shown, the contact extension 54 may be fixed to the contact ring 52 at one end 103 and configured to move (e.g., slide) within the contact ring 52 at the other end 104, wherein the central portion 105 flexes toward the rotating stud 40, thereby ensuring electrical contact when the rotating stud 40 rotates relative to the contact ring 52.

[0046] The arrangement and configuration of the radially oriented, spring-loaded, highly conductive fins 99 also allow for varying degrees of misalignment between the contact ring 52 and the rotating stud 40 due to the manufacturing, assembly, and / or wear of these parts. Example Figure 3D and Figure 3ECross-sectional views of the contact ring 52, fin 99, and rotating stud 40 are provided. For example, Figure 3D A rotating stud 40 is shown, coaxially aligned with the contact ring 52, such that each of the contact ring 52 and the rotating stud 40 shares the same axis 110A. If movement of the rotating stud 40 results in misalignment, the rotating stud 40 may be pushed (e.g., in direction 112), which could lead to misalignment between the rotating stud 40 and the contact ring 52. For example, the rotating stud 40 may correspond to a second axis 110B that is offset from the axis 110A of the contact ring 52. In this case, the fin 99 maintains reliable contact with the rotating stud 40 because the fin 99 is spring-loaded toward the rotating stud 40.

[0047] Bearing 56 also surrounds the rotating stud 40 to support the stud during rotational motion. Bearing 56 may be arranged around the rotating stud 40 between the contact rings 52, 53 and the flange end 46 of the rotating stud 40. In some examples, bearing 56 is a needle roller bearing using relatively long and / or thin cylindrical needle rollers similar to needles. Needle roller bearings may be used around the rotating stud 40 to reduce friction and withstand any bending / misalignment forces between the rotating stud 40 and the connector pin 34. Needle roller bearings may be thinner and provide a thinner profile between the rotating stud 40 and the inner housing 50. In some examples, other types of bearings may be used to suit the specific application.

[0048] For example, an elastic offset member 58, such as a wave spring, can be arranged between the bearing 56 and the flange end 46 of the rotating stud 40. This offset member 58 provides limited axial movement between the rotating stud 40 and the bearing 56. By using the disclosed bearing 56, axial movement of the rotary connector does not interrupt the contact between the rotating stud 40 and the contact ring 52 (and / or contact extension 54). For example, when the rotary power connector 26 is connected to the single cable 18, the hinged movement of the single cable 18 can cause the rotating stud 40 to compress, elongate, or bend within the housing 30. By using the offset member 58, a degree of axial flexibility or support is provided along the length of the rotating stud 40.

[0049] In some examples, the inner housing 50 is configured to receive contact rings 52, 53 such that each contact ring is fixed relative to the housing. Contact extensions 54, 55 (e.g., fins) are offset toward surface 41 to make electrical contact with the rotation shaft 40. In some examples, the contact extensions 54, 55 are integrated into or combined with the inner housing 50.

[0050] As shown in the disclosed figures, the rotary power connector 26 enables the transmission of electricity because current can be transferred from the rotary stud 40, through the contact extensions 54, 55, and into the connector pin 34. The interface between the outer surface 41 and the contact extensions 54, 55 is a sliding interface along the path of current transmission to the rotary power connector 26. Other interfaces are fixed or firmly connected and immovable. For example, the connector pin 34 and the rotary stud 40 may be made of a conductive material. The inner housing 50 may be made of a conductive material, and the contact rings 52, 53 may be made of a conductive material. The outer housing 30 may be made of an insulating material, such as plastic, thereby protecting the exterior of the rotary power connector 26 from short-circuit connections to external components and / or devices (e.g., robot arm 22).

[0051] The tubular connector pin 34 and the tubular swivel stud 40 are axially aligned along the longitudinal axis 32 of the housing 30, thereby forming a hollow channel 66. In this arrangement, the connector pin 34 and the swivel stud 40 pass through the hollow channel 66 to deliver welding consumables (e.g., electrode wire, welding shielding gas, etc.). Figure 2C An illustration of an example rotary power connector 26 enclosed in a housing 30 is provided, wherein a tubular connector pin 34 and a tubular rotary stud 40 extend from the housing.

[0052] In some examples, one or more of the contact extensions 54, 55 are arranged within and / or integrated with one or more of the connector pin 34 or the swivel stud 40 of the rotary power connector 26. For example, the contact extensions 54, 55 are offset toward the inner surface 43 of the inner housing 50 to provide electrical contact between one or more contact extensions 54, 55 and the inner surface 43 during rotation of the rotary power connector 26 relative to the single cable 18.

[0053] For example, one or more contact extensions 54, 55 (e.g., multiple fins) are configured with a first end and a second end. In some examples, each contact extension is fixed at its first end to the outer surface of the rotating stud 40 and offset at its second end to push the fin toward a direction that engages with the inner surface 43.

[0054] In some examples, no contact rings 52, 53 are used. In some examples, one or more contact rings 52, 53 are used to surround the rotating stud 40, wherein one or more contact extensions 54, 55 are arranged around one or more contact rings 52, 53. For example, one or more contact extensions 54, 55 extend from the outer surface of one or more contact rings 52, 53 and are oriented outward to contact the inner surface 43 of the inner housing 50.

[0055] In some examples, one or more of the contact extensions 54, 55 are arranged within and / or integrated with the inner housing 50 of the rotary power connector 26 and are offset to contact the rotary stud 40 without using a contact ring.

[0056] Figure 4 Another example of a rotary power connector 26 is shown, configured with an integrated direct crimp connector 60 (e.g., crimp fitting, extrusion fitting, threaded extrusion fitting, etc.). As shown, the direct crimp connector 60 is secured to the insertion housing 50 via fasteners 62 (e.g., threaded and retaining screw connectors), but may also include press-fit, knurled press-fit, snap-fit, screw, bolt, adhesive, weld, brazing, or other types of fasteners. In some examples, the fasteners 62 are secured to the housing 30. The conductors (e.g., copper wire) of the single cable 18 are crimped onto a tapered surface 64 to form a robust electrical connection between the single cable 18 and the crimp connector 60. One or more O-rings 49 form a seal between the rotary power connector 26 and the crimp connector 60 to prevent the leakage of protective gas outside the channel 66 and the leakage of lubricating grease into the channel 66.

[0057] The crimp connector 60 includes a male connector having a flared end 70 and a ridge 68, such that the core tube from the single cable 18 is secured by a snap-fit ​​feature. Figure 5 An illustration of an example rotary power connector 26 enclosed in a housing 30 is provided, wherein a crimp connector 60 extends from a first end of the housing 30 and a tubular connector pin 34 extends from the opposite second end.

[0058] exist Figure 4 and Figure 5 In this example, once coupled with a single cable, one or more electrical conductors are directly connected to the inner housing 50. For example, the inner housing 50 is arranged to conduct power via extensions 54, 55 through electrical contact rings 52, 53 to the connector pin 34. The current then flows through the connector pin 34 and to the contact tip.

[0059] Referring to the accompanying drawings, the connector pin 34 of the rotary power connector 26 is configured to insert into the main housing 12, thereby connecting the single cable 18 to the nozzle assembly 16 of the welding torch 10. In some examples, a single electrical contact ring 52 is used. In some examples, three or more electrical contact rings 52, 53 are used. In some examples, two or more bearings 56 are used, such as arranged around the tubular rotary stud 40 and supporting one or more electrical contact rings 52, as... Figure 2B As shown.

[0060] Rotary stud 40 and / or crimp connector 60 extend from the end of rotary power connector 26 opposite to connector pin 34 and connect to single cable 18. When used with welding torch 10, rotary power connector 26 allows single cable 18 to rotate relative to main housing 12. The rotatable movement of single cable 18 buffers the otherwise rigid connection passing through welding torch 10, thereby significantly reducing the amount of stress on single cable, which may fail under periodic or repetitive torsional movement, thus extending the service life of single cable. Rotary power connector 26 also enables efficient transfer of one or more of current, welding wire, and / or shielding gas from single cable 18 to nozzle assembly 16, a characteristic of some welding processes (e.g., MIG welding processes, etc.).

[0061] In some examples, when the rotary power connector 26 has reached the end of its service life, the entire assembly of the single cable 18 and the rotary power connector 26 is discarded and replaced to replace the rotary power connector. In some examples, the rotary power connector 26 (and / or one or more components thereof) is a replaceable part that can be discarded and replaced with another rotary power connector by loosening (multiple) fasteners, separating the single cable 18 from the rotary power connector 26, and attaching a new rotary power connector to the single cable 18. In some examples, the rotary stud 40 and / or crimp connector 60 may be engaged with the main housing 12 (e.g., via built-in and / or fixed connectors) such that the connector pin 34 mates with the single cable 18 (e.g., via a quick-connect mechanism). In some examples, one or both ends of the rotary power connector 26 are fixedly and / or securely connected to the single cable 18 and / or the main housing 12.

[0062] In some examples, connector pin 34 and / or swivel stud 40 are described as male connectors. In some examples, one or both of connector pin 34 and / or swivel stud 40 may be female connectors. In some examples, one or both of them may also be flanges in the connection design. In some examples, female connectors (e.g., connector pin 34 and / or swivel stud 40) may be integrated into the inner housing 50.

[0063] Although this method and / or system has been described with reference to certain embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted without departing from the scope of this method and / or system. Additionally, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the scope of this disclosure. For example, the blocks and / or components of the disclosed examples can be combined, divided, rearranged, and / or otherwise modified. Therefore, this method and / or system is not limited to the specific embodiments disclosed. Alternatively, this method and / or system will include all embodiments that fall within the scope of the appended claims, both literally and according to the principle of equivalents.

Claims

1. A rotary power connector for an electric welding torch, comprising: An outer casing having a longitudinal axis; A connector pin is disposed within the housing and extends from a first end of the housing, wherein the connector pin is configured to be inserted into a welding torch to connect the rotary power connector to the welding torch; A stud, the stud being disposed within the housing and extending from a second end of the housing, wherein the stud is capable of being connected to a single cable; One or more electrical contact rings are disposed within the housing and surround the connector pin or the stud. Each electrical contact ring includes one or more contact extensions that are spring-loaded and radially offset to extend toward an outer surface of the connector pin or stud to provide electrical contact between the contact extensions and the outer surface during rotation of the rotary power connector relative to a single cable. An inner housing is disposed within the outer housing and surrounds the one or more electrical contact rings, wherein the inner housing contacts the one or more electrical contact rings and the stud or the connector pin to provide a current path for allowing current to flow from the stud through the one or more electrical contact rings and the inner housing and into the connector pin.

2. The rotary power connector as claimed in claim 1, wherein, The connector pin is configured to rotate relative to the one or more electrical contact rings.

3. The rotary power connector as claimed in claim 1, wherein, The stud is configured to rotate relative to the one or more electrical contact rings.

4. The rotary power connector as claimed in claim 3, wherein, Each of the connector pin and the stud includes a central channel for delivering one or more of the protective gas or the welding wire.

5. The rotary power connector of claim 1, further comprising one or more bearings arranged around the stud, the bearings facilitating rotation of the connector pin or the stud relative to the inner housing.

6. The rotary power connector as claimed in claim 5, wherein, The bearing includes a needle roller bearing, which is arranged between one of the one or more electrical contact rings and the first or second end of the housing.

7. The rotary power connector as claimed in claim 1, wherein, The one or more contact extensions include a plurality of spring-loaded, highly conductive fins.

8. The rotary power connector as claimed in claim 7, wherein, Each of the plurality of fins is fixed at a first end to a corresponding electrical contact ring and offset at a second end or at a portion between the first and second ends to push the fin inward toward engagement with the outer surface.

9. An assembly for the rotary motion of a single cable of a welding torch, the assembly comprising: Welding torch single cable; Welding torch; as well as A connector that rotatably connects the welding torch single cable to the torch body, such that the single cable can rotate relative to the torch body, the connector comprising the rotary power connector as claimed in claim 1, wherein: The connector pin is fixedly arranged axially within the housing. The stud is a rotating stud arranged inside the outer casing; The connector pin is in electrical contact with the inner housing; and The at least one contact extension is spring-loaded and offset in the radial direction to contact the rotating stud during its rotational movement.

10. The component of claim 9, wherein, Each of the single cable, the swivel stud, and the connector includes a passage along the same axis for transmitting welding wire or shielding gas to the welding torch.

11. A rotary power connector for an electric welding torch, comprising: An outer casing having a longitudinal axis; A connector pin is disposed within the housing and extends from a first end of the housing, wherein the connector pin is configured to be inserted into a welding torch to connect the rotary power connector to the welding torch; A stud, the stud being disposed within the housing and extending from a second end of the housing, wherein the stud is capable of being connected to a single cable; Inner housing, the inner housing being disposed within the outer housing, and One or more contact extensions are disposed within the housing and surround one or more of the connector pin or the stud. These contact extensions are spring-loaded and offset radially toward the inner surface of the housing to provide electrical contact between the contact extensions and the inner surface during rotation of the rotary power connector relative to the single cable. The inner housing contacts the stud or the connector pin to provide a current path for current to flow from the stud through the one or more contact extensions and the inner housing and into the connector pin.

12. The rotary power connector as claimed in claim 11, wherein, The one or more contact extensions include a plurality of fins, each fin having a first end and a second end.

13. The rotary power connector as claimed in claim 12, wherein, Each of the plurality of fins is fixed to the outer surface of the stud at the first end and offset at the second end to push the fin outward in a direction that engages with the inner surface.

14. The rotary power connector as claimed in claim 11, wherein, The connector pin is configured to rotate relative to the inner housing.

15. The rotary power connector as claimed in claim 11, wherein, The stud is configured to rotate relative to the inner housing.

16. The rotary power connector of claim 11, further comprising one or more bearings arranged around the stud or the connector pin, the bearings facilitating rotation of the connector pin or the stud relative to the inner housing.

17. The rotary power connector as claimed in claim 16, wherein, The bearing includes a needle roller bearing disposed between one or more contact extensions and the first or second end of the housing.

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