What You Must Know About the Wire Feeder: Unsung Hero of the Welding World

User comfort has also become a key benefit to today’s panels. Controls are located in the most ergonomic, user-friendly manner. Many panels also provide convenient features such as a latching feature so the welder does not have to hold down the gun trigger on long welds.

Even the physical mechanisms today strive for simplicity of use. For example, most of today’s wire feeders do not need tools to change the rolls. Tool-less quick connects facilitate easy set-up and easy swap-out.

(3) Enhanced Functionality.
Simple control panels acknowledge that welders need certain functions to be efficient at their jobs. They provide control of these functions in the most user-friends manner possible, making welding an easier process. More sophisticated welders, however, have grown used to controlling every aspect of the welding process.

More intuitive control panels give these welders access to more functions. Typically, the welder holds down a control button on the panel for five seconds to gain access to additional menu features that allow the welder to set more parameters.

Most intuitive panels allow multiple process set-ups. You set all your parameters, and then push a button to save the program. No more scratching a mark on the front panel to remember your settings. As the complexity of the control increases, the memory to recall more program parameters increases.

On the most advanced panels, you can save more than 200 synergetic lines. Shops that work with welding procedures can program the tolerances specified by each procedure, so the welder cannot exceed the specified range. This is very useful in shops where multiple welders might work on the same job.

This also simplifies the job of quality assurance. The most advanced panels even track production statistics and quality functions or aid in quality control.

(4) Upgradability.
In the past, if your functionality requirements changed, your only option was to purchase a new wire feeder. Today, some manufacturers have designed their equipment to work together so you can match the modules that give you what you need in functionality and power.

For example, our newest wire feeders provide the opportunity to upgrade if your requirements change by simply upgrading the panel. You can start with a very simple panel, and if your welding jobs change or as your experience increases and you want more control, you can upgrade to a fully intuitive control with the ability to store multiple parameters for particular jobs.

You can also easily upgrade your power source to achieve the mix of power and functionality you need without having to purchase a new wire feeder.

(5) Ease of Maintenance.
Many of today’s wire feeders offer self-diagnostic abilities, very similar to on-board diagnostics on a car. If things go awry, the control flashes an error code, and in many cases, can even suggest what may be causing the problem.

For example, if the control senses an excessive motor current, it might suggest that the welder replace the gun liner. Often problems can be detected and rectified before they get so serious that extensive repair to the equipment would be necessary.

Modern wire feeders remove the guesswork that leads to inconsistent welding results. They can simplify the welder’s job and improve productivity. If it has been some time since you last looked at upgrading your welding equipment, you might want to consider having a chat with your equipment provider about how a new wire feeder can make your job easier.