Automated arc welding filler rod feeding assembly and arc length control

An automated welding system having a filler rod feed, the automated welding system comprising:

• a handheld welding torch having an electrode tip portion configured to create a molten pool along a weld path;
• a filler rod feeding assembly, comprising:
• a main body having a central opening with a bottom surface and side surfaces;
• a coupling cover removably couplable to the main body adjacent to the side surfaces, the coupling cover together with the bottom and side surfaces configured to at least partially surround and retain the handheld welding torch therein;
• and
• a rod feeding assembly operably coupled to the main body and comprising:
• a first rod support tube and a second rod support tube axially aligned with each other and configured to translate the filler rod therethrough;
• a drive motor having a drive shaft and a drive gear fixed to the drive shaft, the drive gear positioned abutting the filler rod between the first rod support tube and the second rod support tube;
• and
• an idler gear positioned abutting the filler rod opposite from the drive gear, the idler gear imparting a biasing force against the filler rod toward the drive gear for increasing friction between the drive gear and the filler rod,
• wherein rotation of the drive gear by the drive motor causes the filler rod to advance axially through the first and second rod support tubes to the electrode tip portion of the handheld welding torch.