Systems and methods for controlling drive roll contact force in welding-type systems

A wire feeder system for feeding an electrode wire from a wire source to a welding torch along a wire path, the system comprising:

• a motor;
• a first pair of drive rolls driven by the motor are disposed along the wire path closer to the wire source than to the welding torch, wherein the wire is driven between first and second drive rolls of the first pair of drive rolls;
• a second pair of drive rolls disposed along the wire path closer to the welding torch than to the wire source, wherein the wire is driven between drive rolls of the second pair of drive rolls;
• one or more sensors configured to monitor a contact force on the wire from the drive rolls of one of the first or second pairs of drive rolls;
• and
• a controller to:
• receive a feedback signal corresponding to the contact force on the wire from the first and second drive rolls of one of the first or second pairs of drive rolls;
• command a first actuator to change a position of the first drive roll of the first pair of drive rolls relative to the second drive roll of the first pair of drive rolls to adjust a contact force on the wire from the first pair of drive rolls in response to the contact force at the first pair of drive rolls falling outside a first range of threshold contact force values;
• and
• command a second actuator to adjust a contact force on the wire from the second pair of drive rolls in response to the contact force at the second pair of drive rolls falling outside a second range of threshold contact force values.