Abstract: A welding system including a welding power source including power conversion circuitry adapted to receive primary power and to convert the primary power to a weld power output for use in a welding operation and a controller communicatively coupled to the welding power source are provided. The controller is adapted to determine a statistical signature of at least one parameter of a welding process and to utilize the statistical signature to determine at least one of an electrode type, an electrode diameter, and a shielding gas type during the welding operation.

Abstract: A battery charging system which includes a main housing with a main chamber defined by a base, an end panel mounted on each end of the base, and a cover enclosing the end panels. At least one battery charging connector is connected to the housing. A power supply is connected to the at least one battery charging connector, where the power supply provides a battery charging electrical power to the at least one battery charging connector. The power supply has at least one heat generating electrical device. A tunnel is formed at least partially within the main chamber and extends between the end panels in the main chamber. At least one heat generating electrical device at least partially extends into the tunnel to be exposed to air in the tunnel to cool the heat generating electrical device.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: Systems, devices, and methods for measuring a peak to peak switching ripple in a voltage present on welding output terminals are provided. The systems, devices, and methods may also be utilized to determine, during a welding operation, a weld cable inductance based on the measured peak to peak voltage ripple.

Abstract: A battery charging system which includes an input circuit configured to receive an input power and provide an output power on a first output terminal and a second output terminal. An output circuit has a first input terminal connected to the first output terminal and a second input terminal connected to the second output terminal to receive the output power and configured to condition the output power for a battery charging process. A first conductive plate with a first bus surface extends between the first input terminal and the first output terminal. An insulator plate has a first insulator surface disposed in an abutting relationship with the first bus surface and a second insulator surface. A second conductive plate has a second bus surface which extend between the second input terminal and the second output terminal and is disposed in an abutting relationship with the second insulator surface.

Abstract: A technique for dynamically adjusting an output voltage of forward converter circuits for a battery charging operation is provided. The technique allows for varying voltage at the charging battery by manipulating the duty cycles of two forward converter circuits. The present disclosure provides methods and systems for increasing synchronized duty cycles in a pair of forward converter circuits in response to a changing battery charge state that requires a higher voltage output then changing a phase shift between the duty cycles in response to further increases in output voltage demand. The present disclosure also provides methods and systems for setting a phase shift between duty cycles in a pair of forward converter circuits based on battery rating and then altering pulse width in response to changing battery charge state.

Abstract: A system and method, in certain embodiments, adjusts a charging output based on capabilities of various power sources. The system and method may be used to charge a variety of equipment such as welders, cutters, induction heaters, tools and so forth. For example, a charging circuit configured to change an output charge level based upon capabilities of multiple power sources configured to be coupled to the charging circuit. In some embodiments, the system and method may test the capabilities of the various power sources by evaluating an actual output versus a commanded output, and reduce the commanded output if the actual output falls below a desired level.

Abstract: Methods and systems for clearing short circuits during a MIG welding process are disclosed. A method may include detecting a short circuit and increasing output current of a power source at a first ramp rate to clear the short circuit. The method further includes increasing output current at a second ramp rate after the output current reaches a threshold. Power sources and systems implementing the method are also provided.

Abstract: A technique for dynamically adjusting an output voltage for a welding or cutting operation is provided. The technique allows for varying output voltage at the welding or cutting torch by manipulating the duty cycles of two forward converter circuits. The present disclosure provides methods and systems for increasing synchronized duty cycles in a pair of forward converter circuits in response to increasing output voltage demand then changing a phase shift between the duty cycles in response to further increases in output voltage demand. The present disclosure provides a controller designed to receive input signals and generate output pulse width modulation signals that control the duty cycle width and phase shift of the outputs of the forward converter circuits in response to these signals. Methods of accommodating for the time needed for the transformer core to reset via leading edge or lagging edge compensation are provided.

Abstract: A power circuit, in certain embodiments, includes an inductor to limit current through a capacitor, wherein the capacitor is configured to smooth ripple for a constant voltage welding system. More specifically, the power circuit may include a rectifier configured to convert AC power to DC power. The rectifier may be coupled to a DC bus configured to transmit the DC power. A capacitive circuit having the capacitor may be coupled across the DC bus to smooth ripple in the DC power. The inductor, e.g., coupled between the DC bus and the capacitive circuit, limits the rate of current flow between the capacitive circuit and the DC bus during a welding operation, thereby reducing heating in the output capacitive circuit. A further inductor may be coupled to one side of the DC bus to stabilize the rate of current flow from the power circuit to a load.

Abstract: A battery charging system which includes a main housing with a main chamber defined by a base, an end panel mounted on each end of the base, and a cover enclosing the end panels. At least one battery charging connector is connected to the housing. A power supply is connected to the at least one battery charging connector, where the power supply provides a battery charging electrical power to the at least one battery charging connector. The power supply has at least one heat generating electrical device. A tunnel is formed at least partially within the main chamber and extends between the end panels in the main chamber. At least one heat generating electrical device at least partially extends into the tunnel to be exposed to air in the tunnel to cool the heat generating electrical device.

Abstract: A battery charging system which includes an input circuit configured to receive an input power and provide an output power on a first output terminal and a second output terminal. An output circuit has a first input terminal connected to the first output terminal and a second input terminal connected to the second output terminal to receive the output power and configured to condition the output power for a battery charging process. A first conductive plate with a first bus surface extends between the first input terminal and the first output terminal. An insulator plate has a first insulator surface disposed in an abutting relationship with the first bus surface and a second insulator surface. A second conductive plate has a second bus surface which extend between the second input terminal and the second output terminal and is disposed in an abutting relationship with the second insulator surface.

Abstract: A battery-charging system includes a power supply having a high-frequency transformer and is configured to deliver a battery charging power to charge at least one battery. The high-frequency transformer has a bobbin including an elongated top and bottom surfaces and first and second substantially semi-circular end surfaces connecting the top surface with the bottom surface to form an elongated first coil winding surface having a central axis. A first coil is wound around the first coil winding surface, and a second coil is magnetically coupled to the first coil and wound thereto.

Abstract: A portable battery powered welder is disclosed that is configured to operate without an external power source. The portable battery powered welder may include a battery coupled to a welding circuit and a wire feeder. Further, the portable battery powered welder may include a suitcase to integrally support and completely enclose the welding circuit, the battery, and the wire feeder. The suitcase may include a lateral access door having a hinge and a latch. Additionally, the wire feeder and a wire spool may be disposed in a region accessible by the lateral access door. The suitcase may also include an access panel disposed over a region containing the battery. The access panel may be mounted to the case via a snap mount and/or secured via fasteners. Finally, the suitcase may include a top handle and may be made of a lightweight, impact resistant, and flame retardant material.

Abstract: A system and method for operating an inverted-based power source includes a power input configured to receive alternating current (AC) power and a rectifier configured to convert the AC power to direct current (DC) power. The inverter-based power source also includes an inverter configured to receive the DC power from the rectifier and convert the DC power to AC power and a controller configured to generate switching signals according to a pattern of offsets from a regular half period and communicate the switching signals to the inverter or rectifier control operation of the inverter or rectifier.

Abstract: A welder having an internal shielding gas regulator is disclosed. The welder has an internal gas cylinder and an internal regulator disposed in an enclosure. The welder may be equipped with an auxiliary shielding gas cylinder inlet so that a bulk shielding gas cylinder can be attached thereto and have a flow therefrom regulated by the internal shielding gas regulator. The welder constructed according to the invention is highly transportable, compact, and self-sufficient.

Abstract: A system and method for tracking, storing, and distributing inventory of welding-type consumables within an industrial facility includes conveyors for moving and storing welding-type consumables on pallets or other shipment units to the proper work zones. Various sensors or detectors are employed at the loading and unloading ends of the conveyors to provide data for determining quantity, type, and/or location information for monitoring inventory or even automated reordering. Therefore, such a system and method provides robust, reliable, and inexpensive inventory management that can be adaptable and compatible with multiple brands, types, and shipment varieties of inventory materials.

Abstract: A system and method, in certain embodiments, adjusts a charging output based on capabilities of various power sources. The system and method may be used to charge a variety of equipment such as welders, cutters, induction heaters, tools and so forth. For example, a charging circuit configured to change an output charge level based upon capabilities of multiple power sources configured to be coupled to the charging circuit. In some embodiments, the system and method may test the capabilities of the various power sources by evaluating an actual output versus a commanded output, and reduce the commanded output if the actual output falls below a desired level.

Abstract: The present invention is directed to a portable welding-type power source including a removable energy storage device configured to provide a first voltage output and a boost circuit connected to the energy storage device and configured to boost the first voltage output to a second voltage output to supply power to the welding-type power source according to a selected welding-type process.