Multi-diameter power pin and receiving socket

Abstract

Multi-diameter power pins and receiving sockets are disclosed. An electrical connector includes a multi-diameter power pin having a proximal portion having a first diameter, an engagement portion having a second diameter that is less than the first diameter, a support portion having a third diameter that is less than the second diameter, and a threaded distal portion having a fourth diameter that is less than the third diameter. A receiving block having a multi-diameter through-hole is configured to receive the multi-diameter power pin. The receiving block includes a plurality of gaps extending radially from the multi-diameter through-hole to an outer surface of the receiving block, a receiving portion disposed between a lateral surface of the receiving block and a first gap of the plurality of gaps, and a clamping portion disposed between the plurality of gaps.

Description

Technical Field

[0001] This invention relates to the field of electrical connections, and more particularly to a connector for an arc process operating system having multi-diameter power pins and a receiver block. Background Technology

[0002] Generally, a welding robot includes one or more arms, a welding torch, and a wire feeder for feeding welding wire to the torch. The welding torch is located at the distal end of the robot, and the wire feeder is located between the base of the welding torch and the distal end. A cable connects the wire feeder to the welding torch and supplies one or more of power, welding wire, process gas, and cooling fluid from the wire feeder. A tight contact between the power pins of the plug and the receiving block of the socket is desirable for the proper transfer of power and fluid from the wire feeder to the welding torch cable.

[0003] Typically, the user climbs onto the robot to connect the welding torch cable to the wire feeder. The user inserts the welding torch cable plug into the wire feeder socket and holds it in place with one hand while simultaneously clamping the plug onto the socket with the other. Because both hands are busy clamping / secured to the wire feeder, the user has no free hands to stabilize themselves while on the robot. The user may become unstable on the robot and potentially fall. Therefore, the user may not be able to properly secure the cable plug to the socket, resulting in inefficient power transmission, kinked or jammed welding wire, and / or fluid leakage.

[0004] In addition, gaskets are typically placed in the plug and cable to protect the solder wire fed through the connector. The gasket is installed in the cable by inserting it through the power pins of the plug. Once installed, the gasket isolates the solder wire from current and / or fluid flowing through the power pins and cable. Typically, the gasket is held in place by a bolt that passes through the power pin and engages the end of the gasket. The bolt can be loosened or tightened using tools such as a screwdriver or Allen wrench, but overtightening the bolt can damage the gasket, leading to solder wire kinking.

[0005] In view of at least the above-mentioned problems, a connection system is desired for effectively and safely securing the pad inside the welding torch cable and / or connecting the welding torch cable to the power supply and / or wire feeder. Summary of the Invention

[0006] This invention relates to a connector for an arc process system. According to at least one embodiment, an electrical connection system includes multi-diameter power pins having a proximal portion, an engagement portion, a support portion, and a threaded distal portion. The proximal portion has a first diameter. The engagement portion extends from the proximal portion and has a second diameter smaller than the first diameter. The support portion extends from the engagement portion and has a third diameter smaller than the second diameter. The threaded distal portion extends from the support portion and has a fourth diameter smaller than the third diameter.

[0007] Alternatively or concurrently, the electrical connection system may include a receiving block having a multi-diameter through-hole configured to receive multi-diameter power pins. The receiving block includes a plurality of gaps extending radially from the multi-diameter through-holes to an outer surface of the receiving block, a receiving portion disposed between a lateral surface of the receiving block and a first gap among the plurality of gaps, and a clamping portion disposed between the plurality of gaps. Attached Figure Description

[0008] To complete the description and to better understand the invention, a set of accompanying drawings is provided. These drawings form part of the description and illustrate embodiments of the invention, and should not be construed as limiting the scope of the invention, but only as examples of how the invention can be practiced. The drawings include the following figures:

[0009] Figure 1 This is a schematic diagram of a robotic welding system according to an exemplary embodiment.

[0010] Figure 2A This is a perspective view of a wire feeder assembly with a partially transparent housing according to an embodiment.

[0011] Figure 2B According to the embodiments Figure 2A A perspective interior view of a portion of the wire feeder assembly.

[0012] Figure 3A and 3B This is a perspective view of the connector in a first configuration according to an embodiment.

[0013] Figure 3C It is in the second configuration according to the embodiment. Figure 3A and 3B A cross-sectional view of the connector.

[0014] Figure 3D It is in the third configuration according to the embodiment. Figure 3A and 3B A cross-sectional view of the connector.

[0015] Figure 4A This is a perspective view of the power supply pins according to an embodiment.

[0016] Figure 4B yes Figure 4A A cross-sectional view of the power supply pins.

[0017] Figure 5 yes Figure 4A A cross-sectional view of the far end of the power supply pin during installation into the plug.

[0018] Figure 6A This is a perspective view of the socket according to an embodiment.

[0019] Figure 6B yes Figure 6A Side view of the socket.

[0020] Figure 6C It is along Figure 6B A cross-sectional view of the socket taken from line AA.

[0021] Figure 6D It is along Figure 6B A cross-sectional view of the receiver block of the socket, taken from the line BB.

[0022] Figure 7 This is a cross-sectional view of the connector in the third configuration.

[0023] Figure 8A This is a front perspective view of the receiving block according to the second embodiment.

[0024] Figure 8B yes Figure 8A A cross-sectional view of the receiving block. Detailed Implementation

[0025] The following description should not be construed as limiting, but is merely given to illustrate the broad principles of the invention. Embodiments of the invention will be described by way of example with reference to the accompanying drawings, which illustrate the elements and results according to the invention. Embodiments of the invention are described with reference to connectors for wire feeders and welding torch cables, but the embodiments are not limited thereto. For example, connectors can be used to connect and transmit power between any two components of a large power system, such as a power supply and the cable of a plasma cutting welding torch.

[0026] A typical power pin for a plug used in arc process operations (e.g., welding or plasma cutting operations) typically comprises only one or two portions having one or two diameters. For example, a typical power pin may include an attachment portion for attaching to a cable and a second portion configured to be clamped in a receiving block of a receptacle and to receive one or more gases from the receiving block. Typically, the entire second portion is clamped within the receiving block. That is, the clamps of the receiving block are configured to abut against the second portion. The second portion typically includes surface features such as one or more grooves, holes, and / or protrusions configured to receive one or more of process gases, seals, retainer screws, etc.

[0027] When the standard power pins are inserted into the receiver block of the socket, the user must use one hand to hold the plug in place and the other hand to hold the second part within the receiver block. However, if one or more surface features of the second part are not properly aligned with the corresponding structures in the receiver block during this two-handed holding operation, fluids used during arc process operations may leak from the plug and socket. Furthermore, even if the second part is properly aligned within the receiver block, one or more surface features may obstruct the receiver block's clamping, causing a loose connection between the power pins and the receiver block. A loose connection may cause the plug to detach and / or result in poor electrical connection, leading to power loss during operation.

[0028] Generally, the system and method proposed herein for connecting a welding torch cable to a wire feeder includes a plug with multi-diameter power pins and a receptacle with a receiving block having multi-diameter through-holes or apertures for receiving the power pins. Features of the power pins and the receiving block allow a user to connect and secure the plug to the receptacle with one hand. For example, an engagement mechanism provided in the power pin engages the inner surface of the receiving block in response to the pin being inserted into it. The engagement mechanism maintains the position of the power pin while the user clamps and secures it in the receiving block. Therefore, the user can insert the power pin into the receiving block with one hand and temporarily lock it in place using the engagement mechanism, release the welding torch cable, and lock the power pin in place using the clamp.

[0029] Furthermore, compared to conventional connectors, the dedicated support portion of the power pin, corresponding to the dedicated clamping portion of the receiver block, provides an improved electrical connection between the pin and the receiver block. That is, the dedicated support portion and clamping provide unobstructed contact between the power pin and the receiver block. Therefore, electricity can be efficiently conducted between the receiver block and the power pin without the disadvantages of conventional power pins mentioned above.

[0030] In addition, the power pin includes a central hole for receiving a pad extending into the soldering torch cable. The pad isolates the solder wire passing through the connector from the inner surface of the power pin and the conductor of the soldering torch cable. The user can access the central hole of the power pin manually without tools by removing the pad cap and inserting the pad into the central hole using the pad tip. To secure the pad, the user can position the pad cap over the pad tip and the distal portion of the power pin, clamping the pad tip between the pad cap and the power pin. To access or replace the pad, the user can remove the pad cap without tools to expose the pad tip and the distal end of the power pin. Therefore, the pad cap and pad can be easily installed, secured, and / or replaced without the disadvantages of the conventional pad and bolt arrangements described above. Furthermore, the shape of the pad cap helps guide the power pin into the receiving block and prevents solder wire kinking.

[0031] refer to Figure 1 This diagram illustrates an exemplary embodiment of a robotic welding system 1 according to an embodiment. The robotic welding system 1 includes a robot 10 connected to a controller 110, a wire feeder assembly 20, a power supply 130, and a wire spool 140. The power supply 130 is electrically connected to the robot 10 and a welding torch 112 via the controller 110, and is also electrically connected to the wire feeder assembly 20. The power supply 130 can provide power to components of the robot 10, the controller 110, and the wire feeder assembly 20, as well as provide process current for an arc process (e.g., welding or plasma cutting operation). Additionally, the power supply 130 can supply the wire feeder with a shielding gas and / or process gas for a plasma arc process. The controller 110 controls the movement of the robot 10 and the plasma arc process. The wire feeder 140 supplies welding wire to the wire feeder assembly 20. The wire feeder 140 can be a bulk 142 or a spool 144. In some implementations, the spool 144 is disposed within the wire feeder assembly 20.

[0032] In the illustrated embodiment, robot 10 includes a base 100, a first arm 102 pivotally attached to and extending from the base 100, and a second arm 104 opposite to the base 100 and pivotally coupled to the first arm 102. A welding torch 112 is disposed on the distal end 106 of the second arm 104, and a wire feeder assembly 20 is disposed at the connection between the first arm 102 and the second arm 104. However, this is only one example of a welding robot, and this application can be applied to various robots.

[0033] Regardless of the exact configuration of the robot and the position of the wire feeder assembly 20 on the robot, the welding torch cable 114 connects the welding torch 112 to the wire feeder assembly 20. A connector 30 connects the welding torch cable 114 to the wire feeder assembly 20. The connector includes a socket 40 disposed at the wire feeder assembly 20 (see [link to socket]). Figure 2A ) and the plug 50 provided on the welding torch cable 114 (see Figures 3A-3B During welding operations, the welding torch cable 114 delivers process current, welding wire, and fluids (e.g., shielding gas, process gas, and / or cooling fluid) from the wire feeder assembly 20 to the welding torch 112 via the connector 30 and the welding torch cable 114.

[0034] Figure 2AThis is a side perspective view of a wire feeder assembly 20 according to an embodiment. The wire feeder assembly 20 includes a housing 200 having a front end 210 and a rear end 212. The front end 210 includes a connector port 214 and a power port 216, each defining a passage through the front end 210 to an internal compartment 202 defined by the housing 200. A partition wall 220 within the housing 200 divides the internal compartment 202 into a wire feeding side 204 and a control side 206. The wire feeding side 204 receives a socket 40 of a connector 30 and a wire feeder 230 for pulling welding wire through a welding wire port 218 in the rear end 212. The connector port 214 provides a passage for the plug 50 of the connector 30 to be inserted into the socket 40. A conductor 240 for conducting arc process power (see...) Figure 7 It can be plugged into and electrically connected to socket 40 through power port 216, as shown in the following reference. Figure 6A-7 As described.

[0035] The wire feeder 230 includes a plurality of wire rollers 232 for drawing the welding wire from the wire supply 140 across the wire port 218 and pushing the welding wire through the socket 40. The control side 206 includes components and / or circuitry for receiving signals and controlling the wire feeder 230 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 rate, shielding gas flow rate, cooling fluid flow rate, wire feed speed, etc.).

[0036] Figure 2B This is a perspective view of a portion of the wire feeding side 204 of the internal compartment 202. A receiving block 400 of the socket 40 is disposed between and aligned with the wire feeder 230 and the connector port 214. The receiving block 400 is configured to receive the plug 50 and conductor 240 of the connector 30.

[0037] refer to Figures 3A-3D The diagram illustrates three configurations of connector 30. For clarity, the wire feeder assembly 20 housing the socket 40 has been omitted. In configuration C1, the plug 50 is detached and removed from the socket 40 (see Figure 1). Figure 3A and 3B The connector 30 has a plug 50 including a distal end 52 and a proximal end 54 connected to the soldering torch cable 114. A multi-diameter power pin 500 is located at the distal end 52. The receptacle 40 includes a receiver block 400 having a multi-diameter through-hole or center hole 402 for receiving the power pin 500.

[0038] In configuration C2, plug 50 is inserted into socket 40, but is not clamped in place or otherwise locked (see [link]). Figure 3CThe power pin 500 temporarily engages the inner surface of the receiving block 400 that defines the center hole 402 and holds the plug 50 in place. Therefore, the plug 50 cannot disengage from the socket 40 on its own, but the user can manually remove the plug 50 if necessary. See below for reference. Figure 7 The temporary connection configuration C2 between power supply pin 500 and receiver block 400 is discussed in detail.

[0039] In configuration C3, socket 40 is secured by quick-release screw 450 (see...). Figure 3D The receiving block 400 receives and clamps or otherwise locks the plug 50 into place. In locking configuration C3, the receiving block 400 secures the power pin 500 in the center hole 402, making it impossible to remove the plug 50 from the socket 40 without damaging the connector 30 (i.e., non-removably locking the connector 30). See below for reference. Figure 7 The locking configuration C3 between power supply pin 500 and receiver block 400 is discussed in detail.

[0040] Figure 4A and 4B The multi-diameter power pins 500 of the plug 50 are depicted; for clarity, the welding torch cable 114 is omitted. The power pins 500 are configured to receive arc process power (e.g., welding or plasma cutting current), shielding gas, arc process gas, and / or cooling fluid from the receiving block 400. The power pins 500 are also configured to receive welding wire from the wire feeder 230. A center hole 550 extends along a longitudinal axis 501 through the length of the power pins 500. The center hole 550 provides a path for the process and / or shielding gas and the welding wire through the power pins 500. A liner 600 is disposed within the center hole 550. The liner 600 includes an extension tube defining a conduit 602 for receiving the welding wire. Thus, the liner 600 isolates the welding wire from the inner surface of the power pins 500 and the process and / or shielding gas flowing through the center hole 550.

[0041] Power pin 500 includes a proximal portion 510, a contact portion 520 extending from the proximal portion 510, a support portion 530 extending from the contact portion 520, and a threaded distal portion 540 extending from the support portion 530. The proximal portion 510 of the power pin 510 has a diameter d. The diameter d1 of the contact portion 520 is smaller than the diameter d of the proximal portion 510. The diameter d2 of the support portion 530 is smaller than the diameter d1 of the contact portion 520. The diameter d3 of the threaded distal portion 540 is smaller than the diameter d2 of the support portion 530.

[0042] The proximal portion 510 is configured to be attached to the welding torch cable 114 (see [reference]). Figure 3AThe distal end 514 of the proximal portion 510 includes an annular surface 512, and the proximal end 516 includes an end face 517 having one or more fluid ports 518, which are fluidly connected to the central bore 550 via an internal channel 519. Air can be blown through the fluid ports 518 to expel any fluid and clean the internal channel 519 and the central bore 550. Alternatively, cooling fluid can flow through one or more of the internal channel 519 and ports 518 to cool the welding torch 112.

[0043] End face 517 also includes a central hole inlet 552 configured to receive a cable adapter 554. The hole inlet 552 has a larger diameter than the central hole 550. The cable adapter 554 is a cylindrical tube that electrically and fluidly connects the power pin 500 to the cable conductor 115. That is, the cable adapter 554 is configured to receive arc process power (e.g., welding current) and gas from the power pin 500 and to transfer the arc process power and gas to the cable conductor 115. A gasket 600 extends through the cable adapter 554 and the cable conductor 115. The adapter 554 also includes a seal 806 disposed between the inner surface 552A of the hole inlet 552 and the outer surface 554A of the cable adapter 554 to prevent fluid leakage through the hole inlet 552.

[0044] The engagement portion 520 includes a distal end 521, a proximal end 522, an annular surface 523 at the distal end 521, and an outer surface 524. The annular surface 523 is angled relative to the longitudinal axis 501 of the power pin 500. That is, the annular surface 523 is inclined to the longitudinal axis 501 and / or the outer surface 524 of the engagement portion 520 to soften the transition from the engagement portion 520 to the support portion 530 (e.g., to form an inclined surface).

[0045] The mating portion 520 also includes an annular groove 525 extending radially inward from the outer surface 524. The annular groove 525 is fluidly connected to the central bore 550 via one or more radial channels 527. Process gases and / or protective gases can flow to the central bore 550 through the annular groove 525 and the radial channels 527. To prevent leakage, the annular groove 525 is demarcated by a first annular seal 526A and a second annular seal 526B, both extending radially inward from the outer surface 524 and receiving a seal 802. Specifically, the first annular seal 526A is disposed between the distal end 521 of the mating portion 520 and the annular groove 525, while the second annular seal 526B is disposed between the proximal end 522 of the mating portion 520 and the annular groove 525. In other words, the first annular seal 526A is located upstream of the annular groove 525, and the second annular seal is located downstream of the annular groove 525.

[0046] The engagement portion 520 also includes one or more radial holes 528, and one or more engagement mechanisms 700 are disposed in the one or more radial holes 528 (e.g., one mechanism 700 for each hole 528). Each engagement mechanism 700 is configured to engage the inner surface of the receiving block 400 of the socket 40 and temporarily hold the power pin 500 in place. That is, when the plug 50 is inserted into the socket 40, the engagement mechanism 700 prevents the power pin 500 from sliding out of the receiving block 400.

[0047] In the illustrated embodiment, the engagement mechanism 700 includes a ball 710 disposed in a radial bore 528 and a spring 720. The spring 720 is disposed radially inside the ball 710 and applies a radially outward force to the ball 710. The radially outward force causes a portion of the ball 710 to extend beyond the outer surface 524 of the engagement portion 520 a required distance. The engagement mechanism 700 may also include a radial stop 712 to prevent a portion of the ball 710 from extending beyond the outer surface 524 beyond the required distance and / or completely exiting the radial bore 528.

[0048] If a radially inward force greater than the radially outward force from the spring is applied to ball 710, ball 710 can translate completely within the radial hole 528. That is, a portion of ball 710 extending through outer surface 524 can be pushed into radial hole 528, preventing a portion of ball 710 from radially extending beyond outer surface 524. However, a force applied perpendicular to the radial force from the spring (i.e., a force acting axially relative to the power pin) will not cause ball 710 to translate into radial hole 528. Therefore, when engagement mechanism 700 engages receiver block 400, translation of plug 50 along longitudinal axis 501 is prevented.

[0049] In summary, the embodiments are not limited to the engagement mechanism 700 having a ball 710 and a spring 720 configuration. As an example, in some implementations, the engagement mechanism 700 may be an elastic member extending radially from the outer surface 524 of the engagement portion 520. Specifically, the engagement mechanism 700 may include an annular protrusion extending from the outer surface 524. As another example, the engagement mechanism may be a metal, plastic, and / or rubber ring disposed in a second annular groove in the outer surface 524. As yet another example, the engagement portion 520 may include a second annular groove configured to receive the engagement mechanism disposed in the central hole 402 of the receiving block 400.

[0050] While the engagement mechanism 700 is configured to engage the receiving block 400, the support portion 530 of the power pin 500 is configured to be clamped by the receiving block 400. The support portion 530 is specifically designed to provide a large, unobstructed contact area for clamping by the receiving block 400. The support portion 530 includes a distal end 532, a proximal end 534, and a smooth outer surface or support surface 536 disposed between the distal end 532 and the proximal end 534. In other words, the outer surface 536 does not include any surface protrusions or recesses. The smooth outer surface 536 provides consistent contact between the support portion 530 and the inner surface of the receiving block 400 in the clamping configuration C3. This consistent contact provides a uniform clamping force along the support portion 530 and allows for efficient power transfer between the receiving block 400 and the power pin 500, thereby reducing power loss.

[0051] Still referencing Figure 4A and 4B The threaded distal portion 540 is configured to receive and secure a gasket 600 with a gasket cap 610. The threaded distal portion 540 includes a first annular surface, a distal end 542, a proximal end 544, a threaded outer surface 546, and a distal annular surface 548 disposed at the distal end 542. A central hole 550 extends through the distal annular surface 548 and receives the gasket 600. The threaded gasket cap 610 is disposed above the end 620 of the gasket 600 and the threaded distal portion 540. The threaded distal portion 540, the gasket 600, the gasket cap 610, and the end 620 of the gasket are concentrically arranged about a longitudinal axis 501. The threaded distal portion 540 and the gasket cap 610 cooperate to hold the end 620 of the gasket and the gasket 600 in place.

[0052] refer to Figure 5 The image depicts the configuration of a pad 600, a pad cap 610, a pad tip 620, and a threaded distal portion 540 of a power pin 500. The pad cap 610 includes a top wall 611 having an annular surface 611A and circumferential sidewalls 612 having an outer surface 612A and an inner surface 612B. The pad cap 610 also includes a chamfered surface 613 between the annular surface 611A and the outer surface 612A. The chamfered surface 613 facilitates guiding the power pin 500 into the central hole 402 of the receiver block 400.

[0053] The liner cap 610 also includes a first cavity portion 614A and a second cavity portion 614B. The inner surface 612B of the sidewall 612 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 a threaded distal portion 540 of the power pin 500. The inner surface 612B is threaded and configured to engage the threaded outer surface 546 of the threaded portion 540 of the power pin 500. The second cavity portion 614B is configured to accommodate a portion of the liner tip 620 when the cap 610 is engaged with the threaded portion 540 and has a diameter smaller than that of the first cavity portion 614A. Therefore, a user can unscrew the cap 610 to access the threaded portion 540, the liner 600, and the liner tip 620 for maintenance and / or replacement of the liner 600 and the liner tip 620.

[0054] The liner cap 610 also includes a cap inlet 615 disposed in the top wall 611. The cap inlet 615 has a frustoconical shape defined by a cap inlet surface 615A. The frustoconical cap inlet 615 transitions to an expanded outlet 616 defined by an outlet surface 616A. The cap inlet 615 and outlet 616 are fluidly connected to the second cavity portion 614B. That is, the cap inlet 615 and outlet 616 provide a passage through the top wall 611 to the second cavity portion 614B.

[0055] The gasket tip 620 includes a distal end 622, a proximal end 624, and an elongated member or collar 625 extending from the distal end 622 to the proximal end 624. The elongated member 625 includes an inner surface 626 defining a channel 628 for receiving a portion of the gasket 600. The distal end 622 has a diameter larger than the diameter of the elongated member 625 and the diameter of the central bore 550. The diameter difference between the distal end 622 and the elongated member 625 defines a first annular surface 6222. The first annular surface 6222 is configured to abut the distal annular surface 548 of the threaded distal portion 540. Therefore, the distal end 622 of the tip 620 is prevented from passing through the bore 550.

[0056] The distal end 622 also includes a second annular surface 6224 opposite to the first annular surface 6222 and a distal inlet 6202. The distal inlet 6202 has a truncated conical portion 6204 defined by the inner surface 6204A of the distal inlet, and an orifice portion 6206 having a substantially constant diameter defined by the inner surface 6206A of the orifice. The inlet 6202 is fluidly connected to a conduit 602 of the gasket 600.

[0057] During assembly, the gasket 600 and the distal elongation member 625 are inserted into the central hole 550 through the threaded distal portion 540 of the power pin 500. The first annular surface 6222 of the distal end 622 of the gasket tip 620 abuts the distal annular surface 548 of the threaded portion 540 and prevents the gasket tip 620 from completely passing through the hole 550. The gasket cap 610 mates with the threaded distal portion 540 of the power pin 500 to secure the gasket 600 and the gasket tip 620 in place. That is, the gasket cap 610 receives the threaded portion 540 in the first cavity portion 614A and receives the distal end 622 of the gasket tip 620 in the second cavity portion 614B.

[0058] Simultaneously, the distal annular surface 548 of the threaded portion 540 and the inner surfaces 611B and 611C of the second cavity portion 614B restrict the distal end 622 of the gasket tip 620. For example, the distal annular surface 548 may abut against the first annular surface 6222 of the distal end 622, and the inner surface 611C of the cap 610 may abut against the second annular surface 6224. The threaded inner surface 612B of the cap sidewall 612 engages with the threaded outer surface 546 to secure the gasket cap 610 to the threaded portion 540 of the power pin 500. In other words, the threads on the inner surface 612B engage with the threads on the outer surface 546. Thus, the distal end 622 is restricted between the threaded distal portion 540 and the gasket cap 610, securing the gasket tip 620 to the threaded distal portion 540. Because the gasket 600 is fixed to the inner surface 626 of the elongation member 625 of the gasket end 620, the gasket 600 is also fixed in place.

[0059] Now for reference Figures 6A-6D The image depicts a socket 40 and its receiving block 400. The receiving block 400 includes a multi-diameter center hole 402 extending along a longitudinal axis 401 of the receiving block 400, the multi-diameter center hole 402 being configured to receive multi-diameter power pins 500. The receiving block 400 also includes a receiver portion 420, a dedicated clamping portion 430, a distal portion 440, and a quick-release bolt 450 operatively coupled to the clamping portion 430. Furthermore, the receiving block 400 includes a U-shaped connector 460 extending from the bottom of the receiver portion 420 and the clamping portion 430, configured to receive an arc process power conductor 240.

[0060] A multi-diameter center hole 402 extends through the receiver portion 420, the clamping portion 430, and the distal portion 440. The center hole 402 has a diameter D1 passing through the receiver portion 420, a variable diameter D2 passing through the clamping portion 430, and a diameter D3 passing through the distal portion 440. D3 is smaller than diameter D1, while D2 is adjustable to a diameter also smaller than D1. Diameter D2 is changed by tightening the quick-release bolt 450, which is connected to the clamping portion 430. The arrangement of the quick-release bolt 450 and the clamping portion 430 is discussed below.

[0061] The receiver portion 420 includes an inlet 402A that defines a lateral annular surface 421A of the receiver block 400. The inlet 402A has a truncated conical shape defined by the receiver inlet surface 421B. An inner surface 420A of the receiver portion 420 defines a receiver hole segment 402B with a diameter D1 for the central hole 402. A first annular groove 422 (configured to receive the engagement mechanism 700 of the engagement portion 520) and a second annular groove 424 (configured to mate with the annular groove 525 of the engagement portion 520 to define a passage for arc process gas) extend radially outward from the inner surface 420A. The first annular groove 422 has a curved surface 422A. A fluid passage 426 extends radially outward from the second annular groove 424 and ultimately extends to the outer surface of the receiver block 400. The fluid passage 426 fluidly connects the second annular groove 424 to a fluid supply of the wire feeder assembly 20.

[0062] The receiving portion 420 further defines a truncated conical receiver outlet 428 of the receiver aperture section 402B, opposite the aperture inlet 402A. The receiver outlet 428 is defined by an outlet surface 428A extending radially inward and axially toward the clamping portion 430. In other words, the diameter of the section of the central aperture 402 decreases along the receiver outlet 428 toward the clamping portion 430.

[0063] The clamping portion 430 includes an inner surface 430A defining a clamping hole section 402C. The clamping portion 430 includes a first radial gap 432A, a second radial gap 432B parallel to the first radial gap 432A, and a third radial gap 434 extending from the first radial gap 432A to the second radial gap 432B. The first radial gap 432A, the second radial gap 432B, and the third radial gap 434 extend radially from the clamping hole section 402C to one or more outer surfaces of the receiving block 400. Furthermore, the first radial gap 432A, the second radial gap 432B, and the third radial gap 434 define a resilient finger 436 having an upper portion 436A for receiving a quick-release bolt 450.

[0064] In response to the force received from the quick-release bolt 450, the upper portion 436A can translate through the third radial gap 434. That is, the length of the third radial gap 434 can change in response to loosening or tightening the quick-release bolt 450. For example, tightening the quick-release bolt 450 reduces the length of the third radial gap 434 and the diameter D2 of the clamping hole section 402C. Conversely, loosening the quick-release bolt 450 increases the length of the third radial gap 434 and increases the diameter D2 of the clamping hole section 402C. Therefore, the diameter D2 of the clamping hole section 402C varies based on the force applied by the quick-release bolt 450.

[0065] In the illustrated embodiment, a quick-release bolt 450 is disposed in a laterally extending hole 438, which extends from the outer surface of the upper portion 436A of the finger 436 and enters the clamping portion 430 of the receiving block 400. The quick-release bolt 450 includes a handle 4500 and a bolt 4520. The handle 4500 includes a proximal end 4502 and a distal end 4504. The proximal end 4502 includes a cam 4506. The bolt 4520 includes a proximal end 4522 and a threaded distal end 4524, the proximal end 4522 being rotatably coupled to the proximal end 4502 of the handle 4500, and the threaded distal end 4524 for engaging the threads of the lateral hole 438. However, the quick-release bolt 450 is merely a tightening mechanism that can act on the clamping portion 430 (and particularly the finger 436) to lock the power pin 500 in the receiving block 400.

[0066] Furthermore, in the illustrated embodiment, the quick-release bolt 450 can be in the released position when the handle 4500 is in (e.g., Figure 3C In the case of configuration C2 shown, it is screwed into the side hole 438. By rotating the handle from the release position to the clamping position (e.g., Figure 3D The configuration C3 shown allows additional force to be applied to the fingers 436. Rotating the handle 4500 causes the cam 4506 to apply additional force to the fingers 436 and reduce the lateral length of the gap 434. Therefore, the fingers 436 can translate in response to rotation of the handle 4500 from the gripping position to the release position and / or from the release position to the gripping position. However, again, this tightening is merely an example, and in other embodiments, any tightening mechanism can tighten in any manner now known or developed later.

[0067] Still referencing Figures 6A-6D The distal portion 440 of the receiver block 400 includes an inner surface 440A that defines a distal aperture section 402D having a diameter D3. The diameter D3 of the distal aperture section 402D is smaller than the diameter D1 of the receiver aperture section 402B. The distal aperture section 402D is configured to receive the distal portion 540 of the power supply pin 500.

[0068] refer to Figure 6C A U-shaped connector 460 extending from the bottom of the receiver portion 420 and the clamping portion 430 receives the arc process power conductor 240. In the illustrated embodiment, the connector 460 includes a body section 461 and a clamping section 462, the clamping section 462 having an inner surface 463 defining a longitudinally extending receiving aperture 464 configured to receive the conductor 240. That is, the receiving aperture 464 extends in a direction parallel to and radially offset from the longitudinal axis 401 of the receiver block 400 to receive the conductor 240. However, in other embodiments, the connector 460 may have different shapes or positions that define the receiving aperture 464 in different configurations.

[0069] Furthermore, in the illustrated embodiment, a radial gap 467 between the main body section 461 and the clamping section 462 extends radially upward from the receiving hole 464. A first through hole 465A extends laterally through the main body section 461, and a second through hole 465B, coaxial with the first through hole 465A, extends laterally through the clamping section 462. The first through hole 465A and the second through hole 465B receive a clamping bolt 466. The clamping bolt 466 applies force to pull the clamping section 462 toward the main body section 461 until the inner surface 463 of the connector 460 contacts and abuts against the outer surface 242 of the conductor 240, thereby securing the conductor 240 within the receiving hole 464. Thus, the conductor 240 is secured and electrically coupled to the connector 460, and thereby secured and electrically coupled to the receiving block 400. However, again, this is merely an example, and other embodiments may secure the conductor 240 to the connector 460 in any desired manner.

[0070] refer to Figure 7 A cross-sectional view of connector 30 is shown, in which multi-diameter power pins 500 and arc process power conductors 240 are inserted into receiver block 400. Connector 30 is shown in a third configuration C3, in which power pins 500 are clamped to receiver block 400. In this configuration, engagement portion 520 is axially aligned with and received within receiver portion 420, support portion 530 is axially aligned with and received within clamping portion 430, and threaded distal portion 540 is axially aligned with and received within distal portion 440. Receiver hole section 420B (see [reference]) is used to accommodate portions of power pins 500 within a portion of receiver block 400. Figure 6D The diameter D1 is slightly larger than the joint portion 520 (see...). Figure 4B The diameter d1 of the clamping hole section 402C is slightly larger than the diameter d2 of the support portion 530 and the diameter d3 of the threaded distal portion 540, respectively (see [reference]). Figure 4B and 6D ).

[0071] Still referencing Figure 7 The receiver portion 420 is adjacent to the proximal portion 510 of the power pin 500 such that each portion of the power pin 500 is axially aligned with each corresponding portion of the receiver block 400. Specifically, the annular surface 512 of the proximal portion 510 faces and abuts the lateral annular surface 421A of the receiver portion 420. With the power pin 500 aligned with the receiver block 400, the second annular groove 424 of the portion 420 engages with the annular groove 525 of the engaging portion 520 to form an annular fluid channel 800. Additionally, the engaging mechanism 700 engages the first annular groove 422 of the receiver portion 420 to temporarily hold the power pin 500 in the central hole 402.

[0072] For example, the spring 720 of the engagement mechanism 700 pushes a portion of the ball 710 into the first annular groove 422. The ball 710 and the first annular groove 422 prevent axial movement of the power pin 500 unless a radial force sufficient to overcome the force from the spring 720 is applied to the ball 710. The axial force can be transmitted through the power pin 500 to the ball 710, which abuts against a portion of the first annular groove 422. A portion of the axial force can be converted into a radial force in response to the ball 710 abutting against the curved surface 422A of the first annular groove 422. Therefore, if the connector 30 is moved out of its third configuration C3 (e.g., to configuration C2), the user can pull the engagement mechanism 700 out of engagement with sufficient axial force, such that the curved surface 422A converts the axial force into a radial force greater than the spring force.

[0073] As described above, the embodiments are not limited to a single engagement mechanism 700 having a ball 710 and a spring 720 arranged together. In some implementations, the engagement portion 520 may include multiple engagement mechanisms 700. For example, the engagement portion 520 may include two, three, four, or more engagement mechanisms 700 to engage the first annular groove 422 of the receiver portion 420. In some implementations, the engagement mechanism 700 may be an elastic annular ring protruding from or disposed on the engagement portion 520. For example, the engagement mechanism may be a plastic, metal, and / or rubber ring fixed to the engagement portion 520. Alternatively, the engagement mechanism 700 may be a protrusion extending from the outer surface 524 of the engagement portion 520. Alternatively, one or more engagement mechanisms 700 may be disposed in the receiver portion 420, and the first annular groove 422 may be disposed at the engagement portion 520.

[0074] In addition to the receiving engagement mechanism 700, the receiver portion 420 fluidly connects the wire feeder 20 to the welding torch cable 114 via the engagement portion 520. For example, a fluid channel 426, an annular fluid channel 800 (e.g., annular grooves 424 and 525), an internal channel 519, a pin center hole 550, and a cable conductor 115 form a fluid passage from the wire feeder assembly 20 to the welding torch 112. Seals 802 disposed in the first annular seal 526A and the second annular seal 526B of the engagement portion 520 prevent process gas leakage from the annular fluid channel 800. Additional sealing members of the receiver portion 420 are provided by an annular surface 523 adjacent to the outlet surface 428A and an annular surface 512 adjacent to the lateral annular surface 421A. Thus, process gas flowing through the fluid channel 800 is prevented from leaking out of the receiver hole section 402B (see...). Figure 6D The process gas leaks out and passes through receiver section 420. To further protect connector 30 from fluid leakage, seal 806 prevents process gas from leaking through cable adapter 554, and seals 807 and 808 prevent process gas from leaking through gasket cap 610 and gasket tip 620, respectively. Seals 802, 806, 807, and 808 may be O-rings.

[0075] Still referencing Figure 7 Once the engaging portion 520 is engaged and fluidly connected to the receiver portion 420, the user can use the quick-release bolt 450 (see...). Figure 3C-3D The clamping portion 430 is clamped onto the support portion 530 to place the connector 30 in its clamping configuration C3. This presses the fingers 436 into the gap 434 until the inner surface 430A presses against or abuts the support surface 536 of the support portion 530. As described above, the support surface 536 does not include any surface features that would prevent the inner surface 430A from contacting the support surface 536. Therefore, the fingers 436 can effectively clamp the support portion 530 into place and secure the plug 50 in the socket 40. Furthermore, the contact between the inner surface 430A and the support surface 536 electrically connects the receiving block 400 to the power pin 500.

[0076] During operation, power from conductor 240 is conducted through receiver block 400 to power pin 500, and then through cable adapter 554 to cable conductor 115. For example, current is conducted from conductor 240 through receiver block 400 to U-connector 460, where power is conducted from inner surface 430A to support surface 536 of support portion 530. The current is then conducted through cable adapter 554 and cable conductor 115 to welding torch 112. Additionally, process gas flows from wire feeder assembly 20 into annular fluid channel 800 through fluid channel 426. The process gas then passes through pin internal channel 519, pin center hole 550, cable adapter 554, and cable conductor 115 to welding torch 112.

[0077] In addition to electricity and process gas, the welding wire is guided to the welding torch 112 via power pin 500 and torch cable 114. As described above, the welding wire is pulled from the welding wire feeder 140 via welding wire roller 232 and isolated from the current and process gas via pad 600. The welding wire guide 900, supported in the wire feeder assembly 20 by guide support 910, receives the welding wire from the welding wire roller 232 and guides the welding wire to the multi-diameter center hole 402. The threaded distal portion 540, having a pad cap 610 and a cap inlet 615, is radially aligned with the welding wire guide 900. The welding wire enters the cap 610 via the cap inlet 615. The cap inlet surface 615A guides the welding wire radially inward toward the pad tip inlet 6202. The tip inlet inner surface 6204A guides the welding wire radially inward toward the pad guide 602. Both the cap inlet surface 615A and the end inlet inner surface 6204A prevent the welding wire from kinking and / or getting stuck after it leaves the welding wire guide 900. A liner 600 (extending to the welding torch 112 via the welding torch cable 114) guides the welding wire to the welding torch 112, where it is consumed during the arc welding process. The liner 600, liner cap 610, and liner end 620 isolate the welding wire received in the conduit 602 from the gas flowing through the power pin 500 and prevent contact between the welding wire received in the conduit 602 and the inner surface of the power pin 500 defining the central aperture 550.

[0078] Now for reference Figure 8A and 8B The diagram illustrates a receiving block 1400 according to a second embodiment. The receiving block 1400 is similar to the receiving block 400, except that the clamping bolt 466 for holding the conductor 240 is replaced with a quick-release bolt 1466 similar to the quick-release bolt 450. The clamping portion of the receiving block and the configuration of the U-shaped conductor connector are adjusted to accommodate the quick-release bolt 1466. For simplicity, only the differences between the receiving block 400 and the receiving block 1400 will be discussed.

[0079] like Figure 8AAs shown, the receiver block 1400 includes a receiver portion 1420, a clamping portion 1430, a distal portion 1440, and a U-shaped conductor connector 1460. As... Figure 8B As shown, the U-shaped conductor connector 1460 includes a body section 1461 that extends downward at an angle relative to the vertical axis 1401 from the bottom of the receiving block 1400. A clamping portion 1462 extends upward from the body section 1461 to define a longitudinally extending receiving aperture 1464.

[0080] A first through-hole 1465A extends laterally through the main body section 1461, and a second through-hole 1465B, coaxial with the first through-hole 1465A, extends laterally through the clamping section 1462. The first through-hole 465A and the second through-hole 465B receive a quick-release bolt 1466. To accommodate the quick-release bolt 1466, the first through-hole 465A and the second through-hole 465B extend at an inclined angle relative to the vertical axis 1401. When clamped, the quick-release bolt 1466 applies force to pull the clamping section 1462 toward the main body section 1461 until the inner surface 1463 of the connector 1460 contacts and abuts against the outer surface 242 of the conductor 240, thereby securing the conductor 240 within the receiving hole 1464. Thus, the conductor 240 is secured and electrically connected to the U-shaped conductor connector 1460, and thereby secured and electrically connected to the receiving block 1400.

[0081] In the illustrated embodiment, the clamping portion 1430 includes an inner surface 1430A for engaging the power pin 500. The clamping portion 1430 includes a first radial gap 1432A and a second radial gap 1432B parallel to the first radial gap 1432A. The first radial gap 1432A and the second radial gap 1432B extend perpendicularly to the vertical axis 1401. A third radial gap 1434 extends from the first radial gap 1432A to the second radial gap 1432B. The first radial gap 1432A, the second radial gap 1432B, and the third radial gap 1434 extend radially from the inner surface 1430A to one or more outer surfaces of the receiving block 1400. Additionally, the first radial gap 1432A, the second radial gap 1432B, and the third radial gap 1434 define a resilient finger 1436 having a lateral portion 1436A for receiving a quick-release bolt 450. The resilient finger 1436 extends in a direction substantially perpendicular to the vertical axis 1401.

[0082] like Figure 8BAs shown, a quick-release bolt 450 is disposed in a vertically extending hole 1438, which extends from the outer surface of the lateral portion 1436A of the finger 1436 into the clamping portion 1430 of the receiving block 1400. The upper portion 1436A can be translated through the third radial gap 1434 in response to a force received from the quick-release bolt 450. That is, the length of the third radial gap 1434 can vary in response to loosening or tightening the quick-release bolt 450. For example, tightening the quick-release bolt 450 decreases the length of the third radial gap 1434. Conversely, loosening the quick-release bolt 450 increases the length of the third radial gap 1434. Therefore, the length of the third radial gap 1434 can vary based on the force applied by the quick-release bolt 450. Thus, the quick-release bolt 450 can be tightened and loosened to place the clamping portion 1430 in a clamping position (e.g., similar to...). Figure 3D The configuration shown in C3) and the release location (e.g., similar to...) Figure 3C The configuration shown is between C2).

[0083] Therefore, a connector 30 is proposed in which the gasket cap 610 and gasket 600 can be easily installed, secured, and / or replaced without the disadvantages of the conventional gasket and bolt arrangement described above. Furthermore, the user can insert the power pin 500 into the receiving blocks 400 and 1400 with one hand, temporarily lock the plug 50 with the engagement mechanism 700, release the soldering torch cable 114, and clamp and secure the power pin 500 in place with the quick-release screw 450. Thus, power and fluid can be efficiently transferred from the receiving blocks 400 and 1400 to the power pin 500 without the disadvantages of the conventional power pin arrangement described above.

[0084] While the invention has been illustrated and described in detail with reference to specific embodiments thereof, it is not intended to be limited to the details shown, as it will be apparent that various modifications and structural changes can be made therein without departing from the scope of the invention and within the scope and limits of its equivalents. Furthermore, various features from one embodiment can be incorporated into another embodiment. Therefore, it is appropriate that the appended claims be interpreted broadly in accordance with the scope of this disclosure set forth in the appended claims.

[0085] It should also be understood that the welding system 1 or any part thereof described herein can be made of any suitable material or combination of materials, such as plastics, foamed plastics, wood, cardboard, pressed paper, metals, soft natural or synthetic materials (including but not limited to cotton, elastomers, polyesters, plastics, rubber, and their derivatives), 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), etc. Suitable foamed plastics may include expanded or extruded polystyrene, expanded or extruded polypropylene, EVA foam, their derivatives, and combinations thereof.

[0086] Finally, this invention is intended to cover modifications and variations of the invention that fall within the scope of the appended claims and their equivalents. For example, it should be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “inner,” “outer,” “internal,” and “external” as used herein describe reference points only and do not limit the invention to any particular orientation or configuration. Furthermore, the term “exemplary” is used herein to describe examples or illustrations. Additionally, the terms “upstream” and “downstream” are considered to relate to the path of the welding wire (e.g., from…). Figure 7 (The wire guide 900 in the cable conductor 115). Any embodiment described herein as exemplary should not be construed as a preferred or advantageous embodiment, but rather as an example or illustration of a possible embodiment of the invention.

[0087] Similarly, when used herein, the term “comprising” and its derivatives (such as “including”, etc.) should not be construed as having an exclusionary meaning; that is, these terms should not be interpreted as excluding the possibility that the described and defined elements, steps, etc., may be included. At the same time, when used herein, the term “approximately” and its family of terms (such as “approximately”, etc.) should be understood as indicating a value very close to the value of the aforementioned terms. That is, deviations from precise values ​​within a reasonable range should be accepted, as those skilled in the art will understand that such deviations from the indicated values ​​are unavoidable due to reasons such as measurement inaccuracies. The same applies to the terms “almost,” “approximately,” and “substantially.”

Claims

1. A multi-diameter power supply pin for an arc process system, comprising: The proximal portion has a first diameter; A joint portion extending from the proximal portion, the joint portion having a second diameter smaller than the first diameter, the joint portion including an annular groove extending into the outer surface of the joint portion and a fluid channel extending radially from the annular groove to the central hole; The support portion extending from the joint portion has a third diameter smaller than the second diameter; and The threaded distal portion extending from the support portion has a fourth diameter smaller than the third diameter.

2. The power supply pin according to claim 1, wherein, The engagement portion includes an engagement mechanism configured to restrict axial movement of the power pin when it is received in the receiving block.

3. The power supply pin according to claim 2, wherein, The joint also includes radially extending holes; and The engagement mechanism includes a ball support and a spring that are radially translatable and disposed in a radially extending hole.

4. The power supply pin according to claim 1, wherein, The joining part also includes: A first annular seal is disposed upstream of the annular groove; and A second annular seal is located downstream of the annular groove.

5. The power supply pin according to claim 1, wherein, The threaded distal portion includes the threaded outer surface.

6. The power supply pin of claim 1, further comprising a central hole extending along the longitudinal axis of the power supply pin; and A liner extending through a central hole, the liner including a threaded liner cap configured to engage the threaded distal portion.

7. A socket for an arc process system, the socket being configured to receive a power supply pin according to any one of claims 1-6, the socket comprising: A receiving block with multiple diameter through holes, the receiving block comprising: Multiple gaps, the multiple gaps extending radially from a multi-diameter through-hole to the outer surface of the receiving block; The receiving portion is disposed between the lateral surface of the receiving block and the first gap among the plurality of gaps; and The clamping portion is disposed between the plurality of gaps.

8. The socket according to claim 7, wherein, The multi-diameter through-hole has a first diameter at the receiving portion and a second diameter at the clamping portion, the second diameter being smaller than the first diameter.

9. The socket according to claim 7, wherein, The inner surface of the receiving portion includes a first annular groove, which is configured to receive the engagement mechanism when the power pin is inserted into the through-hole.

10. The socket according to claim 9, wherein, The inner surface also includes a second annular groove; and when the power pin is disposed in the through hole, the second annular groove cooperates with the third annular groove disposed in the power pin to form a fluid channel.

11. The socket according to claim 7, wherein, The clamping part includes a quick-release bolt.

12. The socket according to claim 11, wherein, The clamping part can be moved horizontally by tightening and quickly releasing the bolts.

13. The socket according to claim 7, wherein, When the power pin is inserted into the through hole, the clamping portion is configured to support the power pin and prevent the power pin from moving.

14. The socket according to claim 13, wherein, The receiving block is electrically connected to the power supply pin when the clamping part abuts against the supporting part.

15. An electrical connection system, comprising: Multi-diameter power supply pins, including: The proximal portion having the first diameter; A joint portion extending from the proximal portion, the joint portion having a second diameter smaller than the first diameter, the joint portion including an annular groove extending into the outer surface of the joint portion and a fluid channel extending radially from the annular groove to the central hole; A support portion extending from the joint portion, the support portion having a third diameter smaller than the second diameter; and The threaded distal portion extending from the support portion has a fourth diameter smaller than the third diameter; and The receiver block has multi-diameter through-holes configured to receive multi-diameter power supply pins. The receiver block includes: Multiple gaps, the multiple gaps extending radially from a multi-diameter through-hole to the outer surface of the receiving block; The receiving portion is disposed between the lateral surface of the receiving block and the first gap among the plurality of gaps; and The clamping portion is disposed between the plurality of gaps.

16. The electrical connection system according to claim 15, wherein, The inner surface of the receiving portion includes a first annular groove, which is configured to receive a engagement mechanism disposed at the engagement portion when the power pin is inserted into the through hole.

17. The electrical connection system according to claim 16, wherein, The inner surface also includes a second annular groove; and when the power pin is disposed in the through hole, the second annular groove cooperates with the annular groove disposed in the joint portion to form a fluid channel.

18. The electrical connection system of claim 17 further includes an annular seal disposed between the engaging portion and the receiving portion.

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