Universal wire feeder

Abstract

A wire feeder that can be connected to a variety of power supplies which includes a power conditioner that can detect a current and/or voltage level from a particular power supply and modify the current and/or voltage level when required so as to enable the wire feeder to operate in conjunction with the arc welder when connected thereto.

1 . A universal wire feeder designed to be connectable to a different types of power supplies of a different types of arc welders comprising: 
 a power cable designed to be electrically connectable to said power supply of said arc welder;    a welding wire motor designed to feed a consumable welding wire and designed to be at least partially powered by a power supply of an arc welder; and,    a power conditioner at least partially integrated in said wire feeder and designed to detect a current level, a voltage level, a current frequency, or combinations thereof from said different types of power sources from different types of said arc welders, said power conditioner designed to enable the current level the voltage level current frequency, or combinations thereof to pass through said power conditioner unmodified when said detected current level, voltage level, current frequency, or combinations thereof from the power supply of a particular arc welder is compatible to properly power said welding wire motor, said power condition designed to cause the required modification of the current level, the voltage level, current frequency, or combinations thereof that is generated by non-compatible power supply of a particular arc welder so as to enable the non-compatible power supply to properly provide power said welding wire motor.    
   
   
       2 . The universal wire feeder as defined in  claim 1 , wherein said power conditioner includes an AC voltage regulator, a DC voltage regulator, a current limiter, a phase regulator, a frequency regulator, or combinations thereof.  
   
   
       3 . The universal wire feeder as defined in  claim 1 , wherein said power conditioner includes a microprocessor, circuit board, or combinations thereof to detect and at least partially modify said current level, said voltage level, said current frequency, or combinations thereof.  
   
   
       4 . The universal wire feeder as defined in  claim 2 , wherein said power conditioner includes a microprocessor, circuit board, or combinations thereof to detect and at least partially modify said current level, said voltage level, said current frequency, or combinations thereof.  
   
   
       5 . The universal wire feeder as defined in  claim 1 , wherein said power conditioner and said welding wire motor are housed in a unit separate from a unit housing for said power supply of said arc welder.  
   
   
       6 . The universal wire feeder as defined in  claim 3 , wherein said power conditioner and said welding wire motor are housed in a unit separate from a unit housing for said power supply of said arc welder.  
   
   
       7 . The universal wire feeder as defined in  claim 2 , wherein said power conditioner and said welding wire motor are housed in a unit separate from a unit housing for said power supply of said arc welder.  
   
   
       8 . The universal wire feeder as defined in  claim 4 , wherein said power conditioner and said welding wire motor are housed in a unit separate from a unit housing for said power supply of said arc welder.  
   
   
       9 . The universal wire feeder as defined in  claim 1 , including a signal conditioner to receive, send, or combinations thereof, a control signal between said arc welder and said wire feeder, said signal conditioner designed to detect incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof, said signal condition designed to modify incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof to enable a proper control arrangement between said wire feeder and said arc welder.  
   
   
       10 . The universal wire feeder as defined in  claim 5 , including a signal conditioner to receive, send, or combinations thereof a control signal between said arc welder and said wire feeder, said signal conditioner designed to detect incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof, said signal condition designed to modify incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof to enable a proper control arrangement between said wire feeder and said arc welder.  
   
   
       11 . The universal wire feeder as defined in  claim 3 , including a signal conditioner to receive, send, or combinations thereof a control signal between said arc welder and said wire feeder, said signal conditioner designed to detect incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof, said signal condition designed to modify incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof to enable a proper control arrangement between said wire feeder and said arc welder.  
   
   
       12 . The universal wire feeder as defined in  claim 2 , including a signal conditioner to receive, send, or combinations thereof a control signal between said arc welder and said wire feeder, said signal conditioner designed to detect incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof, said signal condition designed to modify incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof to enable a proper control arrangement between said wire feeder and said arc welder.  
   
   
       13 . The universal wire feeder as defined in  claim 8 , including a signal conditioner to receive, send, or combinations thereof a control signal between said arc welder and said wire feeder, said signal conditioner designed to detect incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof, said signal condition designed to modify incompatible control signals to said wire feeder, from said wire feeder, or combinations thereof to enable a proper control arrangement between said wire feeder and said arc welder.  
   
   
       14 . The universal wire feeder as defined in  claim 1 , wherein power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       15 . The universal wire feeder as defined in  claim 9 , wherein power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       16 . The universal wire feeder as defined in  claim 5 , wherein power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       17 . The universal wire feeder as defined in  claim 3 , wherein to said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       18 . The universal wire feeder as defined in  claim 2 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       19 . The universal wire feeder as defined in  claim 13 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       20 . The universal wire feeder as defined in  claim 14 , wherein said connector is detachably connected to said power cable.  
   
   
       21 . The universal wire feeder as defined in  claim 19 , wherein said connector is detachably connected to said power cable.  
   
   
       22 . The universal wire feeder as defined in  claim 21 , including a wire speed selector to select a speed of said welding wire motor.  
   
   
       23 . A method of operating a universal wire feeder by different types of arc welders having different types of power supplies comprising: 
 providing a power cable designed to be electrically connectable to a power supply of said arc welder;    providing a welding wire motor designed to feed a consumable welding wire and designed to be at least partially powered by a power supply of an arc welder;    providing a detection arrangement positioned at least partially in said wire feeder, said detection arrangement designed to detect a current level, a voltage level, a current frequency, or combinations thereof from said power supply and thereby identify compatible and non-compatible power supplies for said welding wire motor;    enabling said detected current level, voltage level, current frequency, or combinations thereof of a compatible power supply to at least partially power said welding wire motor when said detected current level, voltage level and current frequency are compatible to properly power said welding wire motor; and,    providing a modifying arrangement positioned at least partially in said wire feeder to modify said detected current level, voltage level, current frequency, or combinations thereof when said detected current level, voltage level, current frequency, or combinations thereof from an non-compatible power supply is incompatible to power said welding wire motor of said universal wire feeder, said modified current level, voltage level, current frequency, or combinations thereof being compatible to at least partially power said welding wire motor.    
   
   
       24 . The method as defined in  claim 23 , including a power conditioner that modifies said current level, voltage level, current frequency, or combinations thereof, said power conditioner including an AC voltage regulator, a DC voltage regulator, a current limiter, a phase regulator, a frequency regulator, or combinations thereof.  
   
   
       25 . The method as defined in  claim 23 , including the step of detecting a control signal traveling between said arc welder and said wire feeder, and also including the step of determining whether said detected control signal is incompatible to said wire feeder, and further including the step of modifying a detected incompatible control signal to enable a proper control arrangement between said wire feeder and said arc welder, said control signal being an analog signal, a digital signal, an electromagnetic signal, a fiber optic signal, or combinations thereof, said control signal providing a signal for wire feed speed, arc welder identification, welding parameter information, or combinations thereof.  
   
   
       26 . The method as defined in  claim 24 , including the step of detecting a control signal traveling between said arc welder and said wire feeder, and also including the step of determining whether said detected control signal is incompatible to said wire feeder, and further including the step of modifying a detected incompatible control signal to enable a proper control arrangement between said wire feeder and said arc welder, said control signal being an analog signal, a digital signal, an electromagnetic signal, a fiber-optic signal, or combinations thereof, said control signal providing a signal for wire feed speed, arc welder identification, welding parameter information, or combinations thereof.  
   
   
       27 . The method as defined in  claim 23 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       28 . The method as defined in  claim 25 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       29 . The method as defined in  claim 24 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welder welders.  
   
   
       30 . The method as defined in  claim 26 , wherein said power cable includes a universal connector or interchangeable connector designed to be releasably connectable to said power supply of a plurality of different types of said arc welders.  
   
   
       31 . The method as defined in  claim 27 , wherein said connector is detachably connected to said power cable.  
   
   
       32 . The method as defined in  claim 28 , wherein said connector is detachably connected to said power cable.  
   
   
       33 . The method as defined in  claim 29 , wherein said connector is detachably connected to said power cable.  
   
   
       34 . The method as defined in  claim 30 , wherein said connector is detachably connected to said power cable.