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A wire guide module for guiding and changing the direction of wire in a wire dispensing system. The wire guide module having an inner passageway with rollers. The rollers adjacent the inner passageway assist the wire in moving smoothly through the wire guide module as the shape of the inner passagew

A wire guide module for guiding and changing the direction of wire in a wire dispensing system. The wire guide module having an inner passageway with rollers. The rollers adjacent the inner passageway assist the wire in moving smoothly through the wire guide module as the shape of the inner passageway changing the direction of movement of the wire. A wire dispensing system having wire guide modules with rollers which change the direction of the wire while reducing damage to the wire.

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1. A wire guide module, which comprises: a housing having a first end and a second end with a first lateral side and a second lateral side extending from the first end to the second end, the first lateral side defining a first side surface and the second lateral side defining a second lateral side s

1. A wire guide module, which comprises: a housing having a first end and a second end with a first lateral side and a second lateral side extending from the first end to the second end, the first lateral side defining a first side surface and the second lateral side defining a second lateral side surface;an inner passageway defined by the housing and having a fixed shape and extending through the housing from the first end of the housing to the second end of the housing, the inner passageway having a longitudinal length extending from the first end of the housing to the second end of the housing, with openings in the first and second ends of the housing in communication with the inner passageway, wherein the first lateral side is on one lateral side of the passageway and the second lateral side is on the other lateral side of the passageway, such that the passageway is positioned laterally between the first and second lateral sides; anda plurality of first rollers mounted in the first lateral side of the housing, each first roller of the plurality of first rollers disposed at an individual location along the length of the inner passageway and positioned laterally between the first lateral side surface of the housing and the inner passageway;a plurality of second rollers mounted in the second lateral side of the housing, each second roller of the plurality of second rollers disposed at an individual location along the length of the inner passageway and positioned laterally between the second lateral side surface of the housing and the inner passageway;wherein the plurality of first rollers and the plurality of second rollers are located at discrete, fixed, and non-adjustable lateral and longitudinal positions relative to the housing;wherein the passageway is defined in part by an inner passageway wall that extends on one lateral side of the housing between adjacent first rollers and that extends on the other lateral side of the housing between adjacent second rollers;wherein each individual first roller of the plurality of first rollers are offset lengthwise relative to each individual second roller of the plurality of second rollers along the length of the inner passageway such that each individual first roller of the plurality of first rollers do not laterally overlap any of each individual second roller of the plurality of second rollers along the length of the inner passageway such that all of the first rollers mounted in the first lateral side of the housing are longitudinally staggered relative to all of the second rollers mounted in the second lateral side of the housing;wherein the plurality of first rollers are spaced apart longitudinally from each other, and there are no other rollers disposed longitudinally between each individual first roller of the plurality of first rollers on the first lateral side;wherein the plurality of second rollers are spaced apart longitudinally from each other, and there are no other rollers disposed longitudinally between each individual second roller of the plurality of second rollers on the second lateral side;wherein at each individual longitudinal position of each individual first roller of the plurality of first rollers disposed in the first lateral side of the housing, there is no second roller disposed at the same longitudinal position in the second lateral side of the housing such that there is only one roller of the plurality of first rollers and plurality of second rollers disposed laterally adjacent the inner passageway;wherein at each individual longitudinal position of each individual second roller of the plurality of second rollers disposed in the second lateral side of the housing, there is no first roller disposed at the same longitudinal position in the first lateral side of the housing such that there is only one roller of the plurality of first rollers and plurality of second rollers disposed laterally adjacent the inner passageway;wherein the housing is free from any rollers on the second lateral side in areas laterally opposite and across the passageway from the individual locations of the plurality of first rollers disposed in the first lateral side of the housing, and the housing is free from any rollers on the first lateral side in areas laterally opposite and across the passageway from the individual locations of the plurality of second rollers disposed in the second lateral side of the housing. 2. A wire guide module, which comprises: a) a housing having a first end and a second end with a first side and a second side extending longitudinally from the first end to the second end and a first surface and a second surface extending longitudinally from the first end to the second end, the first and second surface also extending laterally from the first side to the second side of the housing, the first end of the housing defining a first end face arranged transverse to both the first and second sides and also the first and second surfaces, the housing further having a first connector flange extending directly from the first surface and the first end face and longitudinally outward therefrom, the housing further having a second connector flange extending directly from the second surface and the first end face and longitudinally outward therefrom, wherein the first connector flange is spaced apart and parallel to the second connector flange, wherein the first and second connector flanges have a planar shape, wherein the first connector flange and second connector flange extend in the same longitudinal direction directly from the first end face;b) an inner passageway extending through the housing from the first end to the second end of the housing with openings in the first and second ends of the housing in communication with the inner passageway; andc) a plurality of rollers mounted in the housing adjacent the inner passageway. 3. The wire guide module of claim 2 wherein the second end of the housing defines a second end face arranged transverse to the first and second sides and the first and second surfaces, and the second end of the housing defines notches in the first and second surfaces of the housing, the notches extending longitudinally inward into the housing directly from the second end face. 4. The wire guide module of claim 1 wherein the rollers extend into the inner passageway. 5. The wire guide module of claim 4 wherein the rollers have a cylindrical shape with an outer surface having a groove and wherein the rollers are positioned adjacent the inner passageway so that a bottom of the groove is in the inner passageway. 6. The wire guide module of claim 5 wherein the housing has a first surface and a second surface extending longitudinally between the ends and laterally between the side surfaces of the housing and wherein the bottom of the groove of the rollers is essentially evenly spaced between the first and second surfaces of the housing. 7. The wire guide module of claim 5 wherein the rollers have a roller housing rotatably mounted on an inner bearing. 8. The wire guide module of claim 7 wherein the roller housing has roller chambers having mounting posts, wherein the inner bearings of the rollers have a center opening adapted to be mounted on the mounting posts and wherein the rollers are rotatably mounted in the roller chambers on the mounting posts. 9. The wire guide module of claim 8 wherein the rollers are mounted on the mounting posts so as to freely rotate on the mounting posts. 10. The wire guide module of claim 2 wherein a first end cap having a passageway with a fitting in the passageway is mounted on the first end of the housing so that the passageway of the first end cap is in communication with the inner passageway of the housing. 11. The wire guide module of claim 10 wherein the first end cap defines an end face and has notches at one end extending inward into the end cap from the end face, wherein the notches are disposed in opposite surfaces of the end cap and the notches mate with the connector flanges on the first end of the housing such that the notches receive the first and second connector flanges to connect the first end cap to the first end of the housing wherein the one end of the first end cap is disposed between the first and second connector flanges on the first end of the housing. 12. The wire guide module of claim 3 wherein a second end cap defines an end face at one end and includes extensions that extend directly outward from the end face in the same direction and from opposite surfaces of the second end cap at the one end in a spaced apart parallel relationship, and the second end cap is mounted on the second end of the housing so that the extensions extend into the notches in the second end of the housing, and the second end of the housing is disposed between the extensions. 13. The wire guide module of claim 10 wherein an insert having a center bore is mounted in and extends into and between the inner passageway of housing and the passageway of the first end cap. 14. The wire guide module of claim 1 wherein ends of the inner passageway adjacent the ends of the housing are enlarged so that the openings at each end of the housing into the inner passageway have a cross-sectional size greater than a cross-sectional size of the inner passageway. 15. The wire guide module of claim 14 wherein the inner passageway has a cylindrical shape and a diameter of the openings in the ends of the housing is greater than a diameter of the inner passageway. 16. The wire guide module of claim 1 wherein the housing is constructed of a rigid material that extends from the first end to the second end and the side surfaces of the housing have a fixed arcuate shape between the ends. 17. The wire guide module of claim 16 wherein the inner passageway has a fixed arcuate shape along a length of the inner passageway between the ends of the housing and between at least two of the first rollers. 18. The wire guide module of claim 17 wherein the inner passageway is evenly spaced between the side surfaces of the housing so that a longitudinal shape of the inner passageway corresponds to the shape of the side surfaces of the housing between the ends. 19. The wire guide module of claim 18 wherein a longitudinal center of the housing is aligned with and the same as the longitudinal center of the inner passageway of the housing. 20. The wire guide module of claim 2 wherein the housing has a first section and a second section which are removably connected together along a plane extending between the sides and ends of the housing to form the housing and wherein the first and second connector flanges extend outward parallel to the plane. 21. The wire guide module of claim 20 wherein the first section of the housing has a first section of the inner passageway and the second section of the housing has a second section of the inner passageway. 22. A method for guiding wire from a wire source to a weld station, which comprises the steps of: a) providing a container for the wire source;b) providing at least two wire guide modules each having a housing constructed of a rigid and non-flexible material and having a first end and a second end with a first side and a second side extending between the ends, an inner passageway extending through the housing between the ends and the sides of the housing having a length between the ends of the housing with a fixed arcuate shape along the length and having openings in the first and second ends of the housing in communication with the inner passageway, and a plurality of rollers mounted in the housing adjacent the inner passageway, wherein the rigid and non-flexible material extends from the first end of the housing to the second end of the housing to define the fixed arcuate shape along the length between the ends;c) providing a first end cap having a passageway and adapted to be mounted on the first end of the housing of one of the wire guide modules;d) providing a second end cap having a passageway and adapted to be mounted on the second end of the housing of the other of the wire guide modules;e) providing a conduit having opposed ends with a passageway extending therebetween;f) connecting the wire guide modules, end caps and conduit together in a correct configuration between the container and the weld station so that the wire guide modules are combined into a wire guide component that is formed by the two wire guide modules, and the wire guide component includes an extended inner passageway formed by the combination of the inner passageways of the wire guide modules, and the extended inner passageway is in communication with the passageways of the end caps and conduit, wherein each wire guide module has a fixed arcuate shape prior to connecting the end caps and wire guide modules together and maintains the same fixed arcuate shape after connecting the end caps and wire guide modules together; andg) feeding the wire from the wire source in the container through the passageways of the wire guide component, end caps and conduit to the weld station. 23. The method of claim 22 wherein each wire guide module has the fixed arcuate shape, wherein a first side of the housing is curved and shorter than a curved second side of the housing, and wherein further in step f), as the wire moves through the wire guide module, a direction of the wire is changed and the wire contacts the rollers positioned between the first side of the housing and the inner passageway. 24. The method of claim 23 wherein the wire guide modules are connected together so that the first end of one of the wire guide modules is connected to the second end of the other of the wire guide modules so that the first side of the housing of the one of the wire guide modules is adjacent the first side of the housing of the other of the wire guide modules so that the inner passageway of one of the wire guide modules is in communication with the inner passageway of the other of the wire guide modules so that the wire guide component is formed from the two connected modules and the wire guide component has the extended inner passageway with a fixed accurate shape with a curvature longer than the curvature of each of the inner passageways of the wire guide modules. 25. The method of claim 22 wherein the wire guide modules are connected together so that the first end of one of the wire guide modules is connected to the second end of the other of the wire guide modules so that the first side of the housing of the one of the wire guide modules is adjacent the second side of the housing of the other of the wire guide modules so that the inner passageway of one of the wire guide modules is in communication with the inner passageway of the other of the wire guide modules so that the wire guide component is formed from the two connected modules and the wire guide component has the extended inner passageway with an S-shape. 26. A method for guiding wire from a wire source to a weld station, which comprises the steps of: a) providing a container for the wire source;b) providing a wire guide module, which comprises: a housing having a first end and a second end with a first lateral side and a second lateral side extending from the first end to the second end, the first lateral side defining a first side surface and the second lateral side defining a second lateral side surface;an inner passageway extending through the housing from the first end of the housing to the second end of the housing, the inner passageway having a longitudinal length extending from the first end of the housing to the second end of the housing, with openings in the first and second ends of the housing in communication with the inner passageway, wherein the first lateral side is on one lateral side of the passageway and the second lateral side is on the other lateral side of the passageway, such that the passageway is positioned laterally between the first and second lateral sides; anda plurality of first rollers mounted in the first lateral side of the housing, each first roller of the plurality of first rollers disposed at an individual location along the length of the inner passageway and positioned laterally between the first lateral side surface of the housing and the inner passageway;a plurality of second rollers mounted in the second lateral side of the housing, each second roller of the plurality of second rollers disposed at an individual location along the length of the inner passageway and positioned laterally between the second lateral side surface of the housing and the inner passageway;wherein each individual first roller of the plurality of first rollers are offset lengthwise relative to each individual second roller of the plurality of second rollers along the length of the inner passageway such that each individual first roller of the plurality of first rollers do not laterally overlap any of each individual second roller of the plurality of second rollers along the length of the inner passageway such that all of the first rollers mounted in the first lateral side of the housing are longitudinally staggered relative to all of the second rollers mounted in the second lateral side of the housing;wherein the plurality of first rollers are spaced apart longitudinally from each other, and there are no other rollers disposed longitudinally between each individual first roller of the plurality of first rollers on the first lateral side;wherein the plurality of second rollers are spaced apart longitudinally from each other, and there are no other rollers disposed longitudinally between each individual second roller of the plurality of second rollers on the second lateral side;wherein at each individual longitudinal position of each individual first roller of the plurality of first rollers disposed in the first lateral side of the housing, there is no second roller disposed at the same longitudinal position in the second lateral side of the housing such that there is only one roller of the plurality of first rollers and plurality of second rollers disposed laterally adjacent the inner passageway;wherein at each individual longitudinal position of each individual second roller of the plurality of second rollers disposed in the second lateral side of the housing, there is no first roller disposed at the same longitudinal position in the first lateral side of the housing such that there is only one roller of the plurality of first rollers and plurality of second rollers disposed laterally adjacent the inner passageway; wherein the housing is free from any rollers on the second lateral side in areas laterally opposite and across the passageway from the individual locations of the plurality of first rollers disposed in the first lateral side of the housing, and the housing is free from any rollers on the first lateral side in areas laterally opposite and across the passageway from the individual locations of the plurality of second rollers disposed in the second lateral side of the housing; c) providing a first end cap having a passageway and adapted to be mounted on the first end of the housing of the wire guide module;d) providing a second end cap having a passageway and adapted to be mounted on the second end of the housing of the wire guide module;e) providing a conduit having opposed ends with a passageway extending therebetween;f) connecting the wire guide module, end caps and conduit together in a correct configuration between the container and the weld station so that the inner passageway of the wire guide module is in communication with the passageways of the end caps and conduit; andg) feeding the wire from the wire source in the container through the passageways of the wire guide module, end caps and conduit to the weld station.