Power pin and receiving socket

Abstract

An electrical connection system for an arc machining system is disclosed. The electrical connection system includes a power pin and a receiving block. The power pin includes an anti-rotation element. The receiving block is configured to receive a power pin and includes a clip assembly and one or more receiving portions. The clamp assembly is configured to selectively engage the power pin to limit axial movement of the power pin relative to the receiving block. The one or more receiving portions are configured to selectively engage the anti-rotation element and prevent rotational movement of the power pin relative to the receiving block.

Description

Technical Field

[0001] This invention relates to the field of electrical connections, and in particular to a connector for an arc machining operating system, the connector having multi-diameter power pins and corresponding receiving blocks. Background Technology

[0002] Typically, a welding robot includes one or more arms, a welding torch, and a wire feeder for feeding welding wire into the torch. The welding torch is positioned at the distal end of the robot, and the wire feeder is positioned on or between the base and distal end of the torch. A cable connects the wire feeder to the welding torch and provides conduits for the transmission of one or more of the following: power, welding wire, process gas, and cooling fluid from the wire feeder to the torch. A tight contact between the power pins of the plug and the receiving block of the socket is ideal to ensure proper transmission of power and fluid from the wire feeder to the welding torch cable.

[0003] Typically, the user climbs onto the robot and connects the welding torch cable to the wire feeder. The user uses one hand to insert the welding torch cable plug into the wire feeder's socket while simultaneously clamping the plug onto the socket with the other hand. Because both hands are busy clamping / secured to the wire feeder, the user has no free hand to stabilize themselves while seated on the robot. Therefore, the user may become unstable on the robot, potentially falling or improperly securing the cable plug to the socket. In turn, improper plug installation can lead to inefficient power transmission, kinking or jamming of the welding wire, and / or fluid leakage.

[0004] In addition, a liner is typically placed in the plug and cable to protect the solder wire fed through the connector. The liner is installed in the cable by inserting it into the power pin of the plug. Once installed, the liner isolates the solder wire from the current and / or fluid flowing through the power pin and cable. Typically, the liner is secured in place by bolts that pass through the power pin and engage with the ends of the liner. The bolts can be loosened or tightened with tools such as screwdrivers and Allen wrenches, but overtightening the bolts can damage the liner, causing the solder wire to twist.

[0005] At least considering the above-mentioned problems, there is a need for a connection system for effectively and safely securing the liner inside the welding torch cable and / or connecting the welding torch cable to a power source and / or a wire feeder. Summary of the Invention

[0006] This document discloses an electrical connection system for an arc machining system. The electrical connection system includes a power pin and a receiving block. The power pin includes an anti-rotation element. The receiving block is configured to receive the power pin and includes a clamping assembly and one or more receiving portions. The clamping assembly is configured to selectively engage the power pin to limit axial movement of the power pin relative to the receiving block. One or more receiving portions are configured to selectively engage the anti-rotation element and prevent rotational movement of the power pin relative to the receiving block. Among other advantages, this electrical system ensures reliable electrical, fluid, and mechanical connections in arc machining systems. Other advantages and aspects are described herein. Attached Figure Description

[0007] To complete the description and better understand the invention, a set of accompanying drawings is provided. These drawings form an integral part of the description and illustrate embodiments of the invention. They should not be construed as limiting the scope of the invention, but rather as examples of how the invention can be practiced. The drawings include the following figures:

[0008] Figure 1 This is a schematic diagram of a robotic welding system according to an exemplary embodiment.

[0009] Figure 2 This is a perspective view of a wire feeder assembly with a partially transparent housing according to an embodiment.

[0010] Figure 3 This is a rear perspective view of the connector in a disconnected configuration according to an example embodiment.

[0011] Figure 4 It is in a locked configuration according to the embodiment. Figure 3 Front perspective view of the connector.

[0012] Figure 5 It is along Figure 4 The line cut from 5-5 Figure 3 A cross-sectional view of a portion of the connector.

[0013] Figure 6 yes Figure 3 A cross-sectional view of the clamps included in the connector in the closed position.

[0014] Figure 7 yes Figure 3 A side perspective view of the connector, in which certain parts of the connector's socket are depicted transparently. Detailed Implementation

[0015] The following description should not be considered limiting, but only as an illustration of 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; however, the embodiments are not limited thereto. For example, the connector can be used to connect and transmit power between any two components of a high-power system, such as a power supply and a cable for a plasma cutting welding torch.

[0016] Conventional power plugs for arc processing operations (such as welding or plasma cutting) typically consist of only one or two portions with one or two diameters. For example, a conventional power plug may include an attachment portion for attaching to a cable and a second portion configured to clamp into and receive one or more gases from a receiver block in a receptacle. Indeed, for conventional power plugs, the clamps of the receiver block may be configured to abut against the entire second portion. However, the second portion may also include various features, such as one or more recesses, holes, and / or protrusions configured to receive one or more process gases, seals, retainer screws, etc., complicating the clamping operation.

[0017] Furthermore, when a conventional power plug is inserted into the receiver block of a socket, the user typically needs to use one hand to hold the plug in place and the other hand to clamp the second part of 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 clamping operation, fluids used during arc machining operations may leak from the plug and socket. Moreover, even if the second part is correctly aligned within the receiver block, one or more surface features may still obstruct the clamping of the receiver block, causing a loose connection between the power plug and the receiver block. A loose connection may cause the plug to detach and / or result in poor electrical connections, leading to a power outage during operation.

[0018] Furthermore, many conventional power connections used in arc machining operations attempt to limit axial and rotational movement through a single component or structure. For example, many conventional power connections used in arc machining operations attempt to limit axial and rotational movement through a single clamp that frictionally engages with the outer surface (e.g., circumference) of the power pins. This can be imprecise and may lead to unsafe and / or inefficient current transmission, fluid transmission, and / or mechanical locking. For instance, if the clamp allows axial movement, the plug may not be fully aligned with the socket, thus preventing fluid transmission between the two. As another example, if the clamp allows tilting or rotation, one side of the plug may lose contact with the plug, resulting in electrical transmission concentrated on a portion of the connection, which is inefficient, potentially hazardous, and / or may cause rapid wear.

[0019] Typically, the systems and methods described herein for connecting welding torch cables to wire feeders provide separate axial and rotational locking / restriction. Separating these functions increases the likelihood of success for each. In fact, with the connection system proposed herein, the axial locking / restriction engages only after the rotational locking / restriction, ensuring that the rotational locking / restriction remains during the connection process. Furthermore, in at least some cases, the axial locking / restriction may only engage when the plug is fully inserted into the socket, ensuring fully effective power transfer between them. That is, with the connection system proposed herein, axial locking can produce a reliable electrical connection. The connection system can also create a reliable fluid connection, as fluid connection alignment can be associated with reliable axial alignment for electrical connection.

[0020] In at least some embodiments, the connection system proposed herein 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. The features of the power pins and the receiving block allow a user to connect and secure the plug to the receptacle with one hand. Furthermore, in at least some embodiments, the plug may include a dedicated carrier portion for the power pins, which provides an improved electrical connection between the pins and the receiving block compared to conventional connectors. That is, the dedicated carrier portion provides unobstructed contact between the power pins and the receiving block. Therefore, power can be efficiently conducted between the receiving block and the power pins without the disadvantages of conventional power pins described above.

[0021] Reference 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 reel 140. The power supply 130 is electrically coupled to the robot 10 and a welding torch 112 via the controller 110 and the wire feeder assembly 20, respectively. The power supply 130 can supply power to components of the robot 10, the controller 110, and the wire feeder assembly 20, and provide processing current for arc processing (e.g., welding or plasma cutting operations). Furthermore, the power supply 130 can supply the wire feeder with shielding gas and / or process gas for plasma arc processing. The controller 110 controls the movement of the robot 10 and the plasma arc processing. The wire feeder 140 supplies welding wire to the wire feeder assembly 20. The wire feeder 140 can be a bulk package 142 or a reel 144. In some embodiments, the reel 144 is disposed within the wire feeder assembly 20.

[0022] In the depicted 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 pivotally coupled to the first arm 102 opposite to the base 100. 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 coupling between the first arm 102 and the second arm 102. However, this is only one example of a welding robot, and this application may be applicable to a wide variety of robots.

[0023] 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 60 couples the welding torch cable 114 to the wire feeder assembly 20. The connector includes a socket 70 disposed at the wire feeder assembly 20 (see...). Figure 2 ) and the plug 80 located on the welding torch cable 114 (see Figures 3 to 5 During welding operations, the welding torch cable 114 transmits the processing current, welding wire, and fluids (such as shielding gas, process gas, and / or cooling fluid) from the wire feeder assembly 20 through the connector 60 and the welding torch cable 112 to the welding torch 112.

[0024] Figure 2 This 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 side 210 and a rear side 212. The front side 210 includes a connector port 214 and a power port 216, each defining a passage through the front side 210 to an internal compartment 202 defined by the housing 200. 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 processing power (see...) Figure 4 The connector 30 can be inserted into and electrically coupled to the socket 40 via the power port 216. As described in detail below, the receiver block 1000 of the socket 40 is disposed between and aligned with the feeder 230 and the connector port 214, the feeder 230 being disposed in the internal compartment 202. The receiver block 1000 is configured to receive the plug 50 and conductor 240 of the connector 30.

[0025] In the depicted embodiment, a partition wall 220 within the housing 200 divides the internal compartment 202 into a wire feed side 204 and a control side 206. The wire feed side 204 accommodates a socket 40 of the connector 30 and a feeder 230 for drawing welding wire through a wire port 218 in the rear surface 212. The feeder 230 includes a plurality of wire rollers 232 for drawing the welding wire from the wire supply 140 through 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 feeder 230 based on the received signals. In some embodiments, the components and / or circuitry may control one or more arc processing parameters (e.g., processing power, processing current, voltage, process gas flow rate, shielding gas flow rate, cooling fluid flow rate, wire feed speed, etc.).

[0026] Now go to Figure 3 and Figure 4 The connector 30 shown in this article can be positioned in at least three configurations. Figure 3 The first configuration C1 (i.e., the disconnected configuration) is depicted, in which the clamp assembly 1070 is in the open position P1 and the plug 50 is disconnected from the socket 40. Figure 4 The third configuration C3 (i.e., the locking configuration) is shown, in which the plug 50 is inserted into the socket 40 and the clamp assembly 1070 is in the closed position P2. The second configuration, not shown, is a midpoint or temporary configuration (i.e., a temporary configuration), in which the plug 50 is inserted into the socket 40 (e.g., as...). Figure 4 (as shown), but the clamp assembly 1070 is in the open position P1 (e.g., Figure 3 (As shown). As described below, the socket 40 may include a conductive insert 1050 that can temporarily or temporarily hold the plug 50 in the second configuration when the clamp assembly 1070 moves from its first position P1 to its second position P2 after the plug 50 is inserted into the socket 40. Therefore, a user can connect the plug 50 to the socket 40 with one hand.

[0027] The socket 40 of the connector 30 described herein typically includes a receiving block 1000 having a multi-diameter through-hole or center hole 1002 for receiving a power pin 1100. Meanwhile, the plug 50 of the connector 30 described herein typically extends from a distal end 1102 to a proximal end 1104 for connection to a welding torch cable. The multi-diameter power pin 1100 is located at the distal end 1102. The power pin 1100 is typically configured to receive arc processing power (e.g., welding or plasma cutting current), shielding gas, arc process gas, and / or cooling fluid from the receiving block 1000. More specifically, the power pin 1100 includes a center hole 1150 extending along a longitudinal axis 1101 through the length of the power pin 1100 (see [link to documentation]). Figure 5 The center hole 1150 provides a path through the power pin 1100 for processing power, process gas and / or shielding gas, and welding wire, at least some of which can be received from the feeder 230.

[0028] like Figure 3 As shown, power pin 1100 includes a proximal portion 1110, an engagement portion 1120 extending from the proximal portion 1100, a carrier portion 1130 extending from the engagement portion 1120, and a threaded distal portion 1140 extending from the carrier portion 1130. The diameter of the proximal portion 1110 of power pin 1100 is generally larger than one or more diameters of the engagement portion 1120. However, the diameter of at least a portion of the engagement portion 1120 may also be larger than the diameter of the carrier portion 1130. The diameter of the distal portion 1140 may also be smaller than the diameter of at least a portion of the engagement portion 1120. Or, in short, the diameter of power pin 1100 may generally decrease from its proximal end 1104 to its distal end 1102 (through various steps). Thus, at least in some respects, it is similar to the power pin disclosed in U.S. Application No. 17 / 215,436, filed March 29, 2021, the entire contents of which are incorporated herein by reference. However, each of the proximal portion 1110, the engagement portion 1120, the bearing portion 1130, and the threaded portion 1140 is described below in sequence.

[0029] First, still refer to Figure 3 and Figure 4 But now combined Figure 5 One end of the proximal portion 1110 is typically configured to be attached to the welding torch cable 114 (see...). Figure 1 At the other end, the proximal portion 1110 may include an annular surface 1112 configured to be positioned near the receptacle 40 when the connector 30 is in its locked configuration C3. For example, when the connector 30 is in its locked configuration C3, the annular surface 1112 may abut against the transverse annular surface 1021A of the hole inlet 1002A of the receptacle 40. The annular surface 112 also defines a step in which the power pin 1100 transitions from the proximal portion 1110 to the engagement portion 1120.

[0030] Second, in the depicted embodiment, the engagement portion 1120 extends from the proximal end 1122 to the distal end 1121 (in... Figure 5(Depicted in dashed lines), and includes an outer surface 1124 in which various features are formed. Moving from the proximal end 1122 to the distal end 1121, the outer surface 1124 includes radial protrusions 1129, a first annular seal 1126A, a first annular groove 1125, a second annular seal 1126, and a second annular groove 1138 formed therein. Furthermore, in the depicted embodiment, the outer surface 1124 is stepped at the step 1128, such that the engagement portion 1120 includes multiple diameters. In particular, a first portion of the outer surface 1124 includes a larger diameter and extends from the proximal portion 1110 to the annular groove 1125. Then, the annular groove 1125 is formed at or defines the step 1128, such that a second portion of the outer surface 1124 includes a smaller diameter and extends from the annular groove 1125 to the bearing portion 1130. However, other embodiments do not require the inclusion of the step 1128, or may include multiple steps 1128.

[0031] In the depicted embodiment, the larger diameter segment of the outer surface 1124 includes a radial protrusion 1129 that extends radially beyond the outer surface 1124. As described below, the radial protrusion 1129 is typically configured to engage with a receiving portion 1022 (i.e., a rotation limiting groove) in the outer surface of the receiving block 1000, such as the transverse annular surface 1021A of the aperture inlet 1002A in the receiving block 1000. When engaged in this way, the radial protrusion 1129 can limit or prevent rotational movement of the power pin 1100 relative to the receiving block 1000.

[0032] In the depicted embodiment, the radial protrusion 1129 is configured to engage one of the receivers 1022 because the radial protrusion 1129 is substantially cylindrical, while the receiver 1022 is hemispherical. Therefore, the radial protrusion 1129 and the receiver 1022 can fit tightly together when they are adjacent to or very close to each other. However, in other embodiments, the radial protrusion 1129 and / or the receiver 1022 can be of any shape and / or size to allow these features to engage when the power pin 1100 is mounted in the receiver block 1000 and to prevent or limit rotational movement of the power pin 1100 relative to the receiver block 1000. Furthermore, while the depicted embodiment shows one radial protrusion 1129, other embodiments may include any number of radial protrusions 1126. For example, some embodiments may include a plurality of radial protrusions 1129 spaced circumferentially around the power pin 1100. The angular spacing around the power pin 1100 can be any desired spacing, but preferably matches the spacing of the receiving portion 1022 on the receiving block 1000, for example, to allow the power pin 1100 and the receiving block 1000 to be aligned at various angles or aligned at one or more specific angles.

[0033] Both the first annular groove 1125 and the second annular groove 1138 extend radially inward from the outer surface 1124. However, grooves 1125 and 1138 can be used for different purposes. The first annular groove 1125 is generally configured to fluidly couple the power pin 1100 to the receiving block 1000. Meanwhile, the second annular groove 1138 is generally configured to help limit axial movement of the power pin 1100 relative to the receiving block 1000 when the connector 30 is in its locked configuration C3.

[0034] More specifically, the first annular groove 1125 may be fluidly coupled to the central bore 1150 through one or more holes 1127 (also referred to as channels), which extend radially (but not necessarily radially) between the central bore 1150 and the annular groove 1125. Thus, process gases and / or protective gases can flow through the annular groove 1125 and the radial channels to reach the central bore 1150. To prevent leakage, the annular groove 1125 is axially defined by a first annular seal 1126A and a second annular seal 1126B, wherein each annular seal extends radially inward from the outer surface 1124 and accommodates the seal 802. That is, the first annular seal 1126A is disposed between the proximal end 1122 of the engagement portion 1120 and the annular groove 1125, while the second annular seal 1126B is disposed between the distal end 1121 of the engagement portion 1120 and the annular groove 1125. In other words, the first annular sealing seat 1126A is disposed downstream of the annular groove 1125, and the second annular sealing seat 1126B is disposed upstream of the annular recess 1125. However, in other embodiments, these seals and sealing seats may be accommodated in the receiving block 1000.

[0035] Third, the carrier portion 1130 of the power pin 1100 is configured to be securely engaged or “exposed” by the receiving block 1000 or its components. The carrier portion 1130 is dedicated to providing an unobstructed, large contact area for the receiving block 1000 to engage and form a strong, reliable electrical connection. Therefore, in the depicted embodiment, the carrier portion 1130 extends from a proximal end 1134 to a distal end 1132 and has a smooth outer surface 1136 disposed therebetween. In other words, the outer surface 1136 does not include any surface protrusions or recesses.

[0036] Therefore, the smooth outer surface 1136 provides a large contact area, allowing the inner surface of the receiving block 1000 or a component mounted therein to engage with this outer surface in the locking configuration C3. Alternatively, more specifically, the smooth outer surface 1136 provides a large carrier contact, allowing the conductive insert 1050 of the receiving block 1000 to engage with this outer surface in the locking configuration C3. Thus, the carrier portion 1130 allows for efficient and reliable power transfer between the receiving block 1000 and the power pin 1100, thereby reducing power loss in components coupled to the connector 30.

[0037] Fourth, the final segment of the power pin 1100 is the distal portion 1140. The distal portion 1140 includes a threaded exterior that can be detachably coupled to the inner liner 610. Furthermore, the inner liner 610 can be coupled to the inner liner 600. Thus, securing the inner liner 610 to the threaded portion 1140 secures the inner liner 600 within the central bore 1150 of the power pin 1100. The inner liner 600 typically includes an elongated tube defining a conduit for receiving solder wire (or other such consumables) and is configured to isolate the solder wire from the inner surface of the power pin 1100 and to process and / or shield gases flowing through the central bore 1150. In fact, in at least some embodiments, the liner 600 and / or liner cover 610 may be identical or similar to the liner and / or liner cover disclosed in U.S. Application No. 17 / 215,436, filed March 29, 2021, the entire contents of which are incorporated herein by reference. Among other advantages, such a liner and liner cover can allow for installation, maintenance, and / or replacement without tools.

[0038] Still referencing Figures 3 to 5 But now it is particularly emphasized Figure 5 The socket 40 and its receiving block 1000 are typically configured to mate with the power pins 1100 and their various features. Therefore, among other features, the receiving block 1000 also includes a multi-diameter center hole 1002 extending along the longitudinal axis 1001 of the receiving block 1000. The center hole 1002 is typically configured to receive a multi-diameter power pin 1100 and includes: (1) a hole inlet 1002A configured to receive and / or mate with a first portion of the proximal portion 1110 and the engagement portion 1120; (2) a first hole segment 1002B (also referred to as a receiver segment) configured to receive and / or mate with a second portion of the engagement portion 1120; (3) a third hole segment 1002C configured to receive and / or mate with a carrier portion 1130; and (4) a distal hole segment 1002D configured to receive and / or mate with a threaded portion 1140.

[0039] To form these different aperture segments, the receiver block 1000 includes a receiver 1020, an engagement portion 1030, and a distal portion 1040. First, the receiver 1020 has multiple inner diameters to define a first aperture diameter for an aperture inlet 1002A and a first portion of a first aperture segment 1002B, and a second aperture diameter for a second portion of the first aperture segment 1002B. The second aperture diameter is smaller than the first aperture diameter. Then, the engagement portion 1030 defines a constant third diameter for a third aperture segment 1002C. In at least some embodiments, the third diameter is substantially equal to the second aperture diameter (of the receiver 1020). Finally, the distal portion 1040 defines a relatively constant diameter for a distal aperture segment 1002D, which can also be substantially equal to the second aperture diameter, except that the distal aperture segment 1002D may include features that can secure a conductive insert 1050 therein.

[0040] like Figure 3 and Figure 5 As shown, the orifice inlet 1002A defined by receiver 1020 includes a truncated conical inner surface 1021B and a transverse annular surface 1021A. Viewed from within or on a wire feeder including socket 70, the transverse annular surface 1021A is the most outwardly oriented portion of receiver block 1000. Crucially, this transverse annular surface 1021A includes receiving portions 1022 formed therein (e.g., extending axially into the transverse annular surface 1021A). As described above, each receiving portion 1022 is sized and shaped to accommodate a radial protrusion 1129 of proximal portion 1110. This allows the power plug 1100 to be rotatably secured relative to receiver block 1000 (e.g., as shown in the image). Figure 4 (As shown).

[0041] Positioning the receiving portion 1022 on the transverse annular surface 1021A is crucial because the transverse annular surface 1021A faces the plug 80 to be inserted into the socket 70. Therefore, when the plug 80 is fully inserted into the socket 70 (e.g., when the connector 30 is in the locked configuration C3), the proximal portion 1110 of the plug 80 (similar to a flange) is positioned very close to (e.g., abutting) the transverse annular surface 1021A. This ensures that the radial protrusion 1129 prevents the power pin 1100 from rotating relative to the receiving block 1000 only when the power pin 1100 is fully installed within the central hole 1002 of the receiving block 1000. In fact, in at least some embodiments, when the plug 80 is fully inserted into the socket 70 (e.g., when the connector 30 is in the locked configuration C3), the proximal portion 1110 strikes the transverse annular surface 1021A to generate tactile, visual, and / or auditory feedback.

[0042] Now, specifically... Figure 5In addition to the inlet 1002A, the receiver 1020 also defines inner surfaces 1020A and 1020B and an annular groove 1024. The inner surfaces 1020A and 1020B are configured to engage with different diameters of the outer surface 1124 of the engagement portion 1120 of the power pin 1100. Specifically, in the depicted embodiment, the inner surface 1020A has a larger inner diameter and can engage with a larger portion of the outer surface 1124 of the engagement portion 1120. Simultaneously, the inner surface 1020B has a smaller inner diameter and can engage with a smaller portion of the outer surface 1124 of the engagement portion 1120. On the other hand, the annular groove 1024 extends radially outward from the inner surfaces 1020A and / or 1020B and can mate with the annular groove 1125 of the engagement portion 1120 to define a fluid passage for the arc process gas.

[0043] Although not shown, the annular groove 1024 can also be connected to a fluid passage that couples the annular groove 1024 to an external gas source. Thus, the annular groove 1125 can be used to fluidly couple the receiving block 1000 to one or more holes 1127 formed through the power pin 1100 (e.g., via the annular groove 1125), which provide a fluid path from the outer surface of the power pin 1100 to the central hole 1150 of the power pin 1100. Alternatively, simply put, the annular groove 1125 can be used to fluidly couple the central hole 1150 of the power pin 1100 to a gas flow (e.g., from the wire feeder assembly 20).

[0044] Still referencing Figure 5 But now combined Figure 3 , Figure 4 and Figure 7 The receiver 1020 also includes a clamping slot 1026. The clamping slot 1026 extends completely through at least an angular portion of the receiver 1020 to intersect with the first hole segment 1002B and allows at least a portion of the clamping assembly 1070 to extend into the center hole 1002 of the receiver block 1000. Figure 5 As shown, the clamp slot 1026 is configured to align with the second annular groove 1138 of the power pin 1100 when the power pin 1100 is fully inserted into the receiver block 1000 (e.g., when the connector 30 is in locked configuration C3 or a temporary configuration prior to locked configuration C3). The clamp assembly 1070 can then be moved to a fully closed position P2, where it axially secures the power pin 1100 within the receiver block 1000.

[0045] Importantly, the clamp assembly 1070 may not fully move to its closed position P2 until it engages with the second annular groove 1138 of the power pin 1100. Taking this into account, and the location of the clamp groove 1026 (which aligns with the second annular groove 1138 when the power pin 1100 is fully inserted into the receiving block 1000), the clamp assembly 1070 can only move to the fully closed position P2 under specific circumstances. These circumstances might be when the conductive portion of the receiving block (e.g., the conductive insert 1050 and / or the engagement portion 1030) fully engages the carrier portion 1130 of the power pin 1100 to electrically couple the power pin 1100 to the receiving block 1000. Alternatively, simply put, the clamp assembly 1070 is locked to the closed position P2 only when a complete and reliable electrical connection is formed between the power pin 1100 and the receiving block 1000 (e.g., via the conductive insert 1050 and the carrier portion 1130).

[0046] Now, let's switch to a separate location again. Figure 5 The engaging portion 1030 and the distal portion 1040 typically define internal dimensions suitable for accommodating the conductive insert 1050 and positioning the conductive insert 1050 on the carrying portion 1130 of the power pin 1100. For example... Figure 7 As shown, the conductive insert 1050 is a flexible crown-shaped insert having a plurality of fingers 1052 extending from a base or flange 1054. Adjacent resilient fingers 1052 are spaced apart by gaps, so that each resilient finger 1052 is independently resilient or flexible. Thus, when the threaded portion 1140 is inserted into the power pin 1100, the resilient fingers 1052 can push the threaded portion 1140 to center alignment. Alternatively, the resilient fingers 1052 can fully engage the periphery of the power pin 1100 in various positions, orientations, and / or alignments (e.g., tilted in any direction, axially offset from the central axis, etc.).

[0047] In view of this, the engagement portion 1030 has a substantially constant inner surface 1030A to uniformly support the distal end of the resilient finger 1052 and a consistent outer boundary to which the distal end of the resilient finger 1052 can be bent. Similarly, the distal portion 1040 has a substantially constant inner surface 1040A to support the base of the resilient finger 1052, but may also include features that can secure the flange 1054 of the conductive insert 1050 within the distal portion 1040 of the receiving block 1000. For example, the inner surface 1040A may include one or more grooves, slots, or other such features, and the conductive insert 1050 may be pressed to press corresponding protrusions into these features (and vice versa), securing the conductive insert 1050 in the receiving block 1000.

[0048] Now refer to it again Figures 3 to 5In addition to the features described above, the receiving block 1000 also includes a U-shaped coupler 1060 extending from the bottom of the receiver 1020 and the engagement portion 1030. The coupler 1060 is configured to receive the arc processing power conductor 240. During operation, power from the conductor 240 is conducted through the receiving block 1000 to the power pin 1100, and then through one or more cable adapters and / or cable conductors, delivering current to the arc processing welding torch 112. For example, current can be conducted from the U-shaped coupler 1060 via the engagement portion 1030 and / or the conductive insert 1050 to the carrier portion 1130. Furthermore, process gas flows from the wire feeder assembly 20 through the receiving block 1000 via the annular groove 1024 and / or the annular groove 1125 into the central hole 1150. The process gas can then flow around the liner 600 to another channel, one or more adapters, and / or one or more conductors, reaching the processing welding torch 112.

[0049] In addition to the power supply and process gas, the welding wire is guided to the welding torch 112 via the power pin 1100 and the torch cable 114. As described above, the welding wire is drawn from the wire feeder 140 by the wire roller 232 and isolated from the current and process gas by the liner 600. In at least some embodiments, the wire guide 900, which may be supported in the feeder assembly 20 by the guide support 910, receives the welding wire from the wire roller 232 and guides it through the distal portion 1140 of the power pin 1100 and / or using the liner cap 610 to the multi-diameter center hole 1002. The liner 600 (which extends through the torch cable 114 to the torch 112) then guides the welding wire to the torch 112, where it is consumed during the arc welding process. The liner 600 and the liner cover 610 (potentially coupled to the liner end) isolate the welding wire from the gas and electricity flowing through the power pin 1100 and the receiver block 1000.

[0050] Now go to Figure 6 and Figure 7 In the illustrated embodiment, the clamp assembly 1070 includes a biased lever clamp. Therefore, the clamp assembly 1070 includes a lever clamp element 1073 mounted on a shaft 1071. In at least some embodiments, the shaft 1071 includes a biasing element 1072 (e.g., a torsion spring) that biases the clamp assembly 1070 toward its open position P1. However, the clamp element 1073 may be specifically designed to engage the power plug 1100 in a manner that overcomes the bias of the biasing element 1072 and secures the clamp assembly 1070 to the power plug 1100.

[0051] More specifically, the clamping element 1073 may include a first member 1074 and a second member 1075 opposite to the first member 1073. Between the first member 1074 and the second member 1075, the clamping element 1073 may include a recessed extension 1076 that allows the first member 1074 and the second member 1075 to bend relative to each other. Thus, when the clamping element 1073 is pressed into contact with the power plug 1100, the first member 1074 and the second member 1075 can bend around the outer periphery of the power plug 1100 and engage with opposite sides of the power plug 1000 (e.g., opposite ends of the diameter of the power plug 1100).

[0052] However, in at least some embodiments, the first member 1074 and the second member 1075 may not be fully locked in place until they are aligned with the second annular groove 1138 of the engagement portion 1120. When such alignment is achieved, the clamp assembly 1070 can engage the power pin 1100 to: (a) prevent axial movement of the power pin 1100 relative to the receiving block 1000; (b) lock the rotation limiting feature in the engaged state; (c) ensure a reliable and complete electrical connection between the power pin 1100 and the receiving block 1000; and (d) establish a sealed fluid connection between the power pin 1100 and the receiving block 1000.

[0053] This is because the first member 1074 and the second member 1075 can be bent around the outer periphery of the second annular groove 1138 of the engagement portion 1120 of the power plug 1100 and tightly engage the groove 1138. In fact, the inner surfaces of the first member 1074 and the second member 1075 can each have a profile that matches the profile of the second annular groove 1138 of the engagement portion 1120. Therefore, when the first member 1074 and the second member 1075 bend around and engage the groove 1138, the first member 1073 and the second member 1075 can lock into place. In fact, in some embodiments, the first member 1074 and the second member 1075 can snap into place, thereby generating tactile and / or acoustic feedback that has achieved reliable (positive) locking. Additionally or alternatively, the first member 1074 and the second member 1075 can generate tactile and / or auditory feedback in any other manner. Furthermore, since the clamp assembly 1070 overcomes the bias when locked in place, it may become rigid and stationary once locked in place, thus providing visual feedback that a reliable lock has been achieved.

[0054] When the clamp assembly 1070 is moved to the locked position P2, the clamp assembly 1070 can secure the connector 30 in its locking configuration C3. The connector 30 will then maintain this connection until the clamp assembly 1070 is opened and / or disengaged. In at least some embodiments, the clamp assembly 1070 includes a cover 1077 with a release flange 1078 to assist the user in gripping and opening the clamp assembly 1070, thereby moving the clamp assembly 1070 to its open position P1. The power pin 1100 can then be removed from the receiving block 1000, during which time the radial protrusion 1129 can disengage from one of the receiving portions 1022.

[0055] Among other advantages, the connector 30 described herein allows a user to insert the power pin 1100 into the receiving block 1000 with one hand and temporarily lock the plug 50 (e.g., via the resilient fingers 1052 of the conductive insert 1050) into the socket 40. The user can then release the welding torch cable 114 and clamp and secure the power pin 1100 in place within the receiving block 1000. Furthermore, once secured in the locking configuration, the connector 30 provides independent axial and rotational locking. At least because these locking functions are independent, a failure of one function will not affect the other. This provides an additional layer of security. Moreover, because these locking features are separate and independent, they are likely to be relatively uncomplicated and reliable, thus ensuring that the connector 30 provides reliable mechanical, electrical, and fluid coupling. In fact, embodiments of this application can ensure that axial and rotational restrictions are only achieved when reliable mechanical, electrical, and fluid coupling is in place. Therefore, power and fluid can be efficiently transferred from the receiving block 1000 to the power pin 1100 without the disadvantages of other couplings in an arc processing system.

[0056] Although the invention has been described in detail with reference to specific embodiments thereof, the invention is not limited to the details shown, as it will be apparent that various modifications and structural changes can be made within the equivalent scope of the claims without departing from the scope of the invention. Furthermore, various features from one embodiment may be incorporated into another embodiment. Therefore, the appended claims should be interpreted broadly and in a manner consistent with the scope of disclosure set forth in the following claims.

[0057] It should also be understood that the connector 30 or a portion thereof described herein may be made of any suitable material or combination of materials, such as plastics, foamed plastics, wood, cardboard, pressed paper, metals, and soft natural or synthetic materials (including but not limited to cotton, elastomers, polyesters, plastics, rubber, 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 foamed or extruded polystyrene, foamed or extruded polypropylene, foamed EVA, their derivatives, and combinations thereof.

[0058] Finally, this invention is intended to cover modifications and variations thereof within the scope of the appended claims and their equivalents. For example, it should be understood that terms such as “left,” “right,” “upper,” “lower,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “inner,” “outer,” “internal,” and “external” that may be 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., Figure 7 (From the wire guide 900 to the cable conductor 115). Any embodiments described herein as exemplary should not be construed as preferred or advantageous embodiments, but rather as examples or illustrations of possible embodiments of the invention.

[0059] Similarly, when used herein, the term "comprising" and its derivatives (such as "including") 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 content may include other elements, steps, etc. At the same time, when used herein, the term "probably" and its family of terms (such as "approximately") should be understood as indicating a value very close to 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 indicated values ​​are unavoidable due to reasons such as measurement inaccuracies. The same applies to terms such as "approximately," "about," and "substantially."

[0060] Clause 1. An electrical connection system for an electric arc machining system, comprising:

[0061] A power plug including an anti-rotation element; and a receiving block configured to receive the power plug, the receiving block including: a clamping assembly configured to selectively engage the power plug to restrict axial movement of the power plug relative to the receiving block; and one or more receiving portions configured to selectively engage the anti-rotation element and restrict rotational movement of the power plug relative to the receiving block.

[0062] Clause 2. The electrical connection system according to Clause 1, wherein the receiving block further includes a conductive portion configured to engage the power pin to electrically couple the power pin to the receiving module.

[0063] Clause 3. The electrical connection system according to Clause 2, wherein the conductive portion includes an insert having resilient fingers.

[0064] Clause 4. The electrical connection system pursuant to Clause 2, wherein:

[0065] The power connector includes a carrying portion and a engaging portion, the engaging portion including the anti-rotation element; and

[0066] In the locking configuration of the electrical connection system, the conductive portion of the receiving block engages with the carrying portion to electrically couple the power pin to the receiving block, while the clamping assembly and one or more receiving portions engage with the engagement portion of the power pin.

[0067] Clause 5. The electrical connection system according to Clause 4, wherein the carrying portion has a first diameter, and at least a portion of the engaging portion has a second diameter greater than the first diameter.

[0068] Clause 6. The electrical connection system according to Clause 5, wherein the power pin further includes a proximal portion having a third diameter greater than the second diameter, the proximal portion being configured to be adjacent to the end side of the receiving block.

[0069] Clause 7. The electrical connection system according to Clause 5, wherein the power pin further includes a distal portion having a third diameter smaller than the first diameter, the distal portion being configured to directly or indirectly support a liner extending axially through a central hole of the power pin.

[0070] Clause 8. The electrical connection system according to Clause 1, wherein the power pin includes a recess configured to receive a portion of the clamp assembly in a locking configuration of the electrical connection system.

[0071] Clause 9. The electrical connection system according to Clause 8, wherein the groove is axially spaced from the distal end of the power pin by the bearing portion of the power pin, such that in the locking configuration of the electrical connection system, the bearing portion of the power pin is axially restricted upstream of the groove.

[0072] Clause 10. An electrical connection system according to Clause 8, wherein the clamping assembly includes a clamping element having a first member and a second member, the first member and the second member being configured to engage opposite sides of the groove.

[0073] Clause 11. The electrical connection system according to Clause 8, wherein the clamping assembly is biased to an open position, and the electrical connection system is not in a locked configuration when the clamping assembly is in the open position.

[0074] Clause 12. The electrical connection system according to Clause 8, wherein, in response to being secured in a closed position, the clamping assembly provides visual feedback, tactile feedback, auditory feedback, or a combination thereof, wherein being secured in the closed position moves the electrical connection system to a locking configuration.

[0075] Clause 13. The electrical connection system according to Clause 1, wherein the clamping assembly can only move to a fully closed position when the conductive portion of the receiving block fully engages the carrying portion of the power pin to electrically couple the power pin to the receiving block, wherein the clamping assembly axially fixes the power pin in the receiving block in the fully closed position.

[0076] Clause 14. The electrical connection system according to Clause 13, wherein any one of the one or more receiving parts can engage the anti-rotation element and restrict the rotational movement of the power pin relative to the receiving block when the conductive portion of the receiving block is fully engaged with the carrying portion of the power pin.

[0077] Clause 15. The electrical connection system according to Clause 1, wherein the power pin further includes one or more through holes, and the receiving block is configured to direct fluid to the one or more through holes.

[0078] Clause 16. An electrical connection system according to Clause 15, wherein the receiving block directs the fluid to one or more channels through an annular channel axially defined by a seal.

[0079] Clause 17. A power pin for an arc machining system, comprising: a carrier portion configured to electrically couple the power pin to a conductive portion of a receiving block; and an engagement portion comprising: an anti-rotation element configured to selectively engage a receiving portion of the receiving block to prevent rotational movement of the power pin relative to the receiving block; and a groove configured to receive part of a clamping assembly of the receiving block to prevent axial movement of the power pin relative to the receiving block.

[0080] Clause 18. The power plug as described in Clause 17, wherein the anti-rotation element includes a protrusion configured to be located within the receiving portion when the power plug is fully installed within the receiving block.

[0081] Clause 19. A receiving block for an arc machining system, comprising: an inlet having a transverse annular surface, the inlet including one or more receiving portions, wherein an anti-rotation element of a power pin is selectively fixed in the receiving portion; a first section configured to axially fix the power pin relative to the receiving block and guide fluid through one or more through holes in the power pin; and a second section configured to electrically couple the receiving block to the power pin.

[0082] Clause 20. The receiving block according to Clause 19, wherein the receiving block includes a clamping assembly that axially fixes the power pin relative to the receiving block.

[0083] Clause 21. The receiving block according to Clause 20, wherein the first hole segment includes a clamping groove that extends radially through the first hole segment along an angular portion therethrough to allow the clamping assembly to extend into the center hole of the receiving block.

[0084] Clause 22. The receiving block according to Clause 19, wherein the second aperture segment includes a conductive insert with resilient fingers configured to electrically couple the receiving block to the power pin.

[0085] Clause 23. The receiving block according to Clause 19, wherein the power pin is inserted into the receiving block through the hole inlet, and the first hole segment is disposed between the hole inlet and the second hole segment.

[0086] Clause 24. The receiving block according to Clause 23, wherein the second aperture segment has a second diameter, and at least a portion of the first aperture segment has a first diameter greater than the second diameter.

[0087] Clause 25. The receiving block according to Clause 19, wherein the first aperture includes an internal groove configured to form an annular fluid channel that guides fluid through one or more through holes of the power pin.

Claims

1. A power pin of an electrical connection system for an arc machining system, the power pin comprising: a bearing portion configured to electrically couple the power pin to a conductive portion of a receiving block; and an engagement portion comprising: an anti-rotation element configured to selectively engage a receiving portion of the receiving block to prevent rotational movement of the power pin relative to the receiving block; and a groove configured to receive a portion of a clamp assembly of the receiving block to prevent axial movement of the power pin relative to the receiving block. The anti-rotation element comprises a protrusion configured to be located within the receiving portion when the power pin is fully installed within the receiving block.

2. The power prong of claim 1, wherein, In a locked configuration of the electrical connection system, the bearing portion is engaged with the conductive portion of the receiving block to electrically couple the power pin to the receiving block, while the clamp assembly is engaged with the groove and the anti-rotation element is engaged with the engagement portion of the power pin.

3. The power prong of claim 1 or 2, wherein, The bearing portion has a first diameter and at least a portion of the engagement portion has a second diameter that is greater than the first diameter.

4. The power prong of any of the preceding claims, wherein, The power pin further comprises a proximal portion having a third diameter that is greater than the second diameter, the proximal portion configured to be located immediately adjacent to an end side of the receiving block.

5. The power prong of claim 4, wherein, The power pin further comprises a distal portion having a fourth diameter that is less than the first diameter, the distal portion configured to directly or indirectly support an inner liner that extends axially through a central bore of the power pin.

6. The power prong of claim 4 or 5, wherein, The groove is axially spaced from a distal end of the power pin by the bearing portion of the power pin, such that in the locked configuration of the electrical connection system, the bearing portion of the power pin is axially constrained upstream of the groove.

7. The power prong of any of the preceding claims, wherein, The anti-rotation element engages the receiving portion when the bearing portion fully engages the conductive portion of the receiving block.

8. The power prong of any of the preceding claims, wherein, 9. The power pin of any one of the preceding claims, further comprising one or more through-holes configured to direct a fluid into a central bore of the power pin.

10. A receiving block of an electrical connection system for an arc machining system, the receiving block comprising: a bore entrance having a transverse annular face, the bore entrance comprising one or more receiving portions in which an anti-rotation element of a power pin can be selectively secured; a first bore section configured to axially secure the power pin relative to the receiving block and direct a fluid through one or more through-holes in the power pin; and a second bore section configured to electrically couple the receiving block to the power pin. The first bore section comprises an internal groove that directs the fluid through the one or more through-holes in the power pin, the internal groove being axially bounded by a seal. The receiving block comprises a clamp assembly that axially secures the power pin relative to the receiving block.

11. The receive block of claim 10, wherein, ​ 12. The receive block of claim 10 or 11, wherein, ​ 13. The receive block of claim 12, wherein, The first bore section includes a clamp slot extending radially through the first bore section along an angular portion of the first bore section to allow the clamp assembly to extend into a central bore of the receiving block.

14. The receive block of claim 12 or 13, wherein, The clamp assembly is biased to an open position, and the electrical connection system is not in a locked configuration when the clamp assembly is in the open position.

15. The receive block of any of claims 12-14, wherein, The clamp assembly provides visual feedback, tactile feedback, audible feedback, or some combination thereof in response to being secured in a closed position that moves the electrical connection system to a locked configuration.

16. The receive block of any of claims 12-15, wherein, The clamp assembly includes a clamp element having a first member and a second member configured to engage opposite sides of the power pin.

17. The receive block of any of claims 12-16, wherein, The clamp assembly is only movable to a fully closed position in which the clamp assembly axially secures the power pin in the receiving block when a conductive portion of the receiving block fully engages a load bearing portion of the receiving block to electrically couple the power pin to the receiving block.

18. The receive block of any of claims 10-17, wherein, The power pin is inserted into the receiving block via the bore entrance, and the first bore section is disposed between the bore entrance and the second bore section.

19. The receive block of any of claims 10-18, wherein, The second bore section has a second diameter, and at least a portion of the first bore section has a first diameter that is greater than the second diameter.

20. The receive block of any of claims 10-19, wherein, The second bore section includes a conductive insert having resilient fingers configured to electrically couple the receiving block to the power pin.

21. The receive block of any of claims 10-20, wherein, Any of the one or more receiving portions are capable of engaging the anti-rotation element and limiting rotational movement of the power pin relative to the receiving block when the second bore section fully engages a load bearing portion of the power pin.

22. An electrical connection system for an arc machining system, comprising: a power pin according to any of claims 1-9; and a receiving block according to any of claims 10-21.

Images