Modular quick disconnect system for welding and cutting systems and method of making

A welding system, comprising:

• an arc welding torch handle removably connected to an electrical cable having a first end and a second end, and having identical cable connectors at each end for reversibly and interchangeably engaging with a handle connector on the arc welding torch handle;
• a detachable power connection, wherein the identical cable connectors and the handle connector each respectively comprise one of a first connector or a second connector for matingly connecting to each other, wherein the detachable power connection further comprises:
• a cylindrical male conductor, retained within the first connector along a cylindrical axis, the male conductor matingly received within a cylindrical female conductor, concentrically retained within the second connector along the cylindrical axis;
• a cylindrical aligning insulator of the second connector for enclosing and internally retaining the cylindrical female conductor along the cylindrical axis, further comprising a pair of male protrusions formed on opposing sides along an exterior surface of the aligning insulator;
• a cylindrical locking body of the first connector for retaining the cylindrical male conductor along the cylindrical axis, the cylindrical locking body comprising an interior surface for defining an internal void for matingly receiving the exterior surface of the cylindrical aligning insulator therein, the cylindrical locking body comprising a pair of female recesses formed on opposing sides along the interior surface for matingly engaging the respective pair of male protrusions of the cylindrical aligning insulator;
• and
• a locking nut formed onto one of the first connector or second connector, for releasably securing the first and second connectors together to form the detachable power connection, wherein the locking nut is retained on the second connector and comprises a cylindrical interior surface having a protruding lock feature for engaging with a recessed lock channel formed on a cylindrical exterior surface of the first connector, such that the first connector and second connector are securely retained by engagement of the lock feature with the lock channel.

A reversible electrical cable, comprising:

• a cable first end and a cable second end, wherein the cable first and second ends each end includes an identical cable connector for reversibly and interchangeably engaging with a corresponding connector on one of an arc welding torch handle or a power pin handle, wherein each of the identical cable connectors are configured to releasably secure the corresponding connector together to form a detachable power connection, wherein the identical cable connectors are one of a first connector or a matingly connectible second connector, and wherein the corresponding connector is a respective other of the first connector or the second connector;
• wherein the detachable power connection comprises:
• a male conductor, retained within the first connector, the male conductor matingly received within a female conductor, retained within the second connector;
• an aligning insulator of the second connector for enclosing and internally retaining the female conductor, further comprising at least one first alignment feature formed along an exterior surface of the aligning insulator;
• a locking body of the first connector for retaining the male conductor, the locking body comprising an interior surface for defining an internal void for matingly receiving the exterior surface of the aligning insulator therein, the locking body comprising at least one second alignment feature formed along the interior surface for matingly engaging the respective at least one first alignment feature of the aligning insulator;
• a locking nut formed onto one of the first connector or second connector, for releasably securing the first and second connectors together to form the detachable power connection, and
• the reversible electrical cable further comprises a liner for transporting welding wire and extending continuously within the reversible cable, wherein the liner includes first and second ends that are received and retained within respective first and second threaded caps each retained within the respective identical cable connectors.