Abstract: The invention described herein generally pertains to a system and method for evaluating one or more conditions or preliminary weld condition related to a welding system and/or method that utilizes a welding sequence to perform two or more welds with respective welding schedules. In an embodiment, an operator registration is provided that verifies the operator and identifies welding sequences to which the operator is authorized to perform. In another embodiment, one or more fixture locations are monitored to determine whether a workpiece is accurately configured prior to a welding operation. In still another embodiment, locations on a workpiece can be displayed to assist an operator in performing two or more welds utilizing a welding sequence. Moreover, a wireless system communications a data signal to a welding work cell in which such data is used to identify a welding sequence.

Abstract: Embodiments of the present disclosure are also directed to a web-configuration system that includes at least one processor and one or more tangible, machine-readable media at least collectively including or storing instructions executable by the at least one processor. The instructions include a module configured to limit configuration options for a welding system based on user selection of a power source for the welding system, a module configured to calculate a weld cable size for the welding system based on the user selection of the power source and user selection of an input voltage, a module configured to assign weld cable characteristics based on the weld cable size and a user selected cable length, and a module configured to assemble a welding system order based at least on the user selection of the power source and the weld cable characteristics.

Abstract: If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.

Abstract: A method includes receiving data corresponding to a voltage level over time and a current level over time. The method also includes determining a first ratio corresponding to a voltage ramp percent or a voltage falling edge percent with respect to a peak in the voltage level and determining a second ratio corresponding to a current ramp ratio or a current falling edge ratio with respect to a peak in the current level. The method further includes determining, based on a comparison between the first ratio and the second ratio, whether to increment, decrement, or maintain an inductance compensation estimation value corresponding to an estimated inductance present in one or more secondary components associated with the welding operation.

Abstract: In arc welding, determining a current value to be high in an early stage of the arc period is effective in reducing spatters caused by feeble short circuit in the arc period. In that case, to sharply decrease the voltage that has increased with increase in current, an inductance value of a reactor has to be kept small. However, a small inductance value causes a problem—weakness against disturbance. The present invention provides an arc welding control method that performs arc welding while repeating the short-circuit period and the arc period. According to the method, changing an inductance value relating to welding output in the arc period offers stable arc welding with fewer spatters and insusceptibility to disturbance.

Abstract: A welding-type device has wireless communications to transmit wireless signals comprising at least identification information. The information may be transmitted either automatically or in response to request signals. Such a welding-type device may be configured to communicate with other welding-type devices, a monitoring device, or both. A wireless communication system has at least one welding-type device, at least one wireless communication assembly, and at least one monitoring device and is capable of assisting a user in preventing theft of welding-type devices.

Abstract: A robot controller that controls a tandem arc welding system according to the present invention includes a leading-electrode correcting section that calculates a leading-electrode correction amount, used for correcting a displacement in a left-right direction and an up-down direction, from a leading-electrode changing amount calculated by a leading-electrode processing section; a leading-electrode correcting section that calculates a trailed-electrode correction amount, used for correcting a displacement in a rotational direction, from a trailed-electrode changing amount calculated by a trailed-electrode processing section; a rotational-displacement correction controlling processing section that calculates a rotational-center correction amount for correcting the displacement of the leading electrode; and a robot trajectory planning processing section that corrects a teaching position and a position of a rotational center of a welding torch during tracking correction.

Abstract: A hybrid wire feeder including an energy storage device and a charging circuit are provided. The hybrid wire feeder may selectively alternate between utilization of power from the energy storage device and utilization of power from a welding power supply to power the weld and one or more weld sequencing events. Some embodiments provide for the energy storage device to be adapted to discharge during periods when the welding power supply is not outputting power and to recharge from the welding power when the welding power supply is outputting power.

Abstract: A welding-type device has a wireless communication unit to transmit wireless signals comprising at least identification information or location information. The information may be transmitted either automatically or in response to request signals. Such a welding-type device may be configured to communicate with other welding-type devices, a monitoring device, or both. A wireless communication system has at least one welding-type device, at least one wireless communication assembly, and at least one monitoring device and is capable of assisting a user in locating particular welding-type devices, monitoring inventory, preventing theft of welding-type devices, and scheduling preventive maintenance.

Abstract: A welding system user interface module includes a front panel comprising a first input device and a first display screen. The welding system user interface module also includes circuitry comprising a memory storing machine-readable instructions, a processor for executing the machine-readable instructions, and communication circuitry configured to receive UI data from the first input device or a second input device of a remote welding system user interface module, and to broadcast synchronized data to the first display screen and a second display screen of the remote welding system user interface module.

Abstract: A welding system includes a welding power source having a user interface disposed thereon and a weld controller disposed therein and being adapted to generate a welding power output for use in a welding operation. The welding system also includes a personal computer having control circuitry disposed therein and being removably interfaced with the welding power source via a docking mechanism. When the personal computer is docked within the docking mechanism, the personal computer is enabled for receiving operator input, and the control circuitry communicates with the weld controller to coordinate control of a welding operation in accordance with the operator input.

Abstract: A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other.

Abstract: An arc welding system according to the present invention includes a welding power supply for supplying welding power to a welding wire, a welding robot including a welding torch mounted to an arm fore end thereof, and a controller for controlling the welding power supply and the welding robot. The welding power supply and the controller perform communication using digital signals, and the welding power supply outputs, to the controller, a welding power-supply feedback signal obtained at the time of inputting of a welding power-supply sync signal. With that configuration, accurate arc tracking can be realized by using the digital signals.

Abstract: A consumable electrode arc welding method includes the detecting of a constriction formed in a molten droplet of the welding wire so as to reduce the welding current, the detecting of a smoothed value of the welding current, and the feedback controlling of the feed rate of the welding wire so as to make the smoothed value of the welding current correspond to a predetermined current setting value. The constriction detection is performed repetitively in a predetermined cycle. In each time of the repetition, the length of a constriction time, from the constriction detection till the arc generation, is measured. The number of constriction time lengths falling outside a predetermined range is counted. When the counted number is not less than a reference number, the transient response time of the feedback control is made longer.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: The invention relates to a monitoring module (1 . . . 1?) for monitoring an electric arc machining process, sail the module comprising a camera (2), a photo flash lamp (3) and a control system (4) that controls the photo flash lamp (3) and a control system (4) that controls the photo flash lamp (3) in such a way that it illuminates when the camera (2) records the image. According to the invention, said the components (2, 3, 4) are arranged in a common housing (5).

Abstract: A system and method of rating the arc maintainability of an electric arc welding stick electrode by creating an arc between the electrode and a workpiece; moving the electrode along the workpiece while maintaining the arc; decreasing either the current or the voltage until a point is reached where the arc is extinguished; determining the open circuit voltage at the point; and, rating the electrode based upon at least the open circuit voltage point.

Abstract: Values of a current and a voltage from a heating power supply device that supplies a current to a wire electrode and that heats the wire electrode are measured, a load resistance value is calculated by dividing the voltage value by the current value, a resistance increment of the wire electrode is calculated from an increased amount in the load resistance value with reference to the load resistance value and an estimated resistance value, a temperature rise value of the wire electrode is estimated based on a specific resistance of the wire electrode and a temperature coefficient of the specific resistance, and a state of carrying a current to the wire electrode is controlled based on the temperature rise value.

Abstract: A method for root pass welding steel plate and pipe is provided that uses pulse arc welding having a current pulse waveform exhibiting a low constant background current and fixed frequency. The welding process may be performed without a backer or backing material.

Abstract: Systems and methods for selecting a welding output waveform based on characterizing a welding circuit output path with respect to its electrical characteristics. At least one electrical characteristic (e.g., inductance, resistance) of a welding output circuit path connected to a welding power source is determined. A welding output waveform is selected from a plurality of welding output waveforms based on the determined electrical characteristics. As a result, the selected welding output waveform is matched to the welding output circuit path electrical characteristics to provide superior welding performance.

Abstract: A system for detecting welding, and cutting parameters is provided. One embodiment of the system includes an input terminal configured to receive signals corresponding to welding or cutting parameters from a first welding or cutting device. None of the signals carry welding power. The system also includes an output terminal configured to provide the signals to a second welding or cutting device. The system includes conductors coupled between the input terminal and the output terminal and configured to carry the signals between the input terminal and the output terminal. The system also includes control circuitry configured to detect the welding or cutting parameters from the signals.

Abstract: A consumable component for a thermal processing torch is provided. The consumable component includes a consumable component body and a signal device located on or within the consumable component body for transmitting a signal associated with the consumable component. The signal can be independent of a detectable physical characteristic of the consumable component.

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: The welding quality classification apparatus relating to the present invention is an apparatus, wherein a data point indicating feature information of a welded joint to be classified whose welding quality is unknown is mapped to a point in a mapping space which has a dimensional number higher than the number of the features constituting the feature information, and the welding quality of a welded joint to be classified is classified based on which of regions of two welding qualities, which are formed by separating the mapping space with a decision boundary, contains the mapped point, and wherein a discriminant function is determined by adopting a weight which minimizes the sum of the classification error corresponding to classification accuracy of a training dataset and a regularization term having a positive correlation with the dimensional number of the discriminant function as weight for each feature constituting the discriminant function indicating the decision boundary.

Abstract: A method for monitoring resistance welding is provided, which includes receiving an input of waveform data obtained by converting current or voltage applied to a transformer welding gun into a digital signal through a teaching group filter; comparing the input waveform data with acceptance waveform data of current or voltage that is accumulatively stored through a destructive test; determining acceptance of a quality of a corresponding welding product if the input waveform data and the acceptance waveform data are equal or similar to each other within a predetermined error range, and determining rejection of the quality of the corresponding welding product if the input waveform data and the acceptance waveform data are different from each other; and outputting an acceptance or rejection message depending on the result of the determination.

Abstract: Welding systems and programming tools are described, in which a touch screen-based welding system configuration tool is provided having a touch screen display for designing welding power source waveforms or for configuring a system sequence controller, where the touch screen may be integrated into a welding system component. The touch screen displays information related to a switching type welding power source and/or a welding system sequence controller, as well as one or more touch activation indicia to allow a user to numerically or graphically configure the power source or the sequence controller by touching the touch activation indicia.

Abstract: A system and method of rating the arc maintainability of an electric arc welding stick electrode by creating an arc between the electrode and a workpiece; moving the electrode along the workpiece while maintaining the arc; decreasing either the current or the voltage until a point is reached where the arc is extinguished; determining the open circuit voltage at the point; and, rating the electrode based upon at least the open circuit voltage point.

Abstract: If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.

Abstract: A welding system includes a first sensor associated with a welding helmet and configured to sense a parameter indicative of a position of a welding torch relative to the welding helmet. The travel speed sensing system also includes a processing system communicatively coupled to the first sensor and configured to determine a position of the welding torch relative to a workpiece based on the sensed first parameter.

Abstract: The present invention concerns an electrical or electronic apparatus, in particular welding machine or battery charger, comprising processing and controlling electronic means (M1, M2) connected to a sensing electronic means (S1, S1?, TR0, VT1, RT1, CT1, R8, CT2, Z1, Z2, Z3, Z4, Z5, Z6, Z7, R4, CT3, ST1, ST2, D12, Q1) from which it receives one or more detection signals of one or more electrical and/or physical quantities related to an apparatus operation, said processing and controlling electronic means (M1, M2) being capable to determine one or more conditions of apparatus operation on the basis of said one or more detection signals, the apparatus being capable to be power supplied through a plurality of terminals (F, N, GND) by a mains comprising a ground conductor to which a ground terminal (GND) of said plurality of terminals (F, N, GND) is connectable, the apparatus being characterised in that said sensing electronic means comprises or consists of a device (S1) for sensing a connection of the ground term

Abstract: A method of automatically setting a welding parameter for MIG/MAG welding including the following steps: initiating (S1) a parameter setting welding operation; detecting (S2) a response welding current at a present wire feed speed during said parameter setting welding operation; determining (S4) a first function mapping said response welding current to said set wire feed speed; determining (S7) a desired wire feed speed from said first function and said desired welding current.

Abstract: An emergency shut off system for a workspace enclosure, wherein a sensor array is provided for detecting hazardous conditions within the workspace enclosure. A control module is coupled to the sensor array. A pneumatic shutoff line is provided, extending between the control module and a hot work apparatus used in connection with the workspace enclosure. The hot work apparatus is responsive to pressurization of the pneumatic shutoff line to remain in an operational state. The control module is responsive to a signal from the sensor array indicating the existence of a hazardous condition inside the workspace enclosure to depressurize the pneumatic shutoff line. The hot work apparatus is responsive to depressurization of the shutoff line to be rendered non-operational.

Abstract: A torch for connection to an electric arc welding system having a wire feeder, a power source and a weld process controller for the power source. The torch being connected to the front end of a welding gun, which gun has a rear end with a first unique component of a connector. The welding system has a second component of the connector matching the first component. The gun has a communication channel extending from the torch to the first component for transmitting data to the welding system through the connector. The torch has a memory with an identification code outputted on the communication channel to the first component and the system has a decoder circuit connected to the second component and responsive to a selected identification code.

Abstract: A method for quality control of a weld bead made using a welding tool. The method collects, by an optical pyrometer having a high frequency acquisition sensor, at least one signal representative of the temperature of a melted portion of the weld bead, and includes a frequency phase for checking that the recurring frequencies are within an acceptable range of reference frequencies, to determine if the weld bead is defective.

Abstract: Various embodiments of a method for monitoring a machine condition are provided. An embodiment of the present invention provides a method of monitoring a machine condition, comprising the following steps: modeling a normal signal model performed by detecting a signal for monitoring condition of a normal machine and converting the detected signal to a normal signal model in time domain using a hidden Markov model (HMM) algorithm; calculating a probability value data of the monitoring signal at a subject machine performed by detecting a signal for monitoring condition of the subject machine in real-time and converting the detected signal to the probability value data relative to the normal state signal model using the HMM algorithm; and determining a section having deficiency where the probability value data of the monitoring signal at the subject machinery is not maintained constantly relative to the normal signal model.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to at least one of a true energy and true power input to the welding output circuit path.

Abstract: A hand-held tool and tool control includes: an orientation determination unit, which is configured to determine an orientation of the tool as orientation data or orientation-specific data, an output unit, which is operatively connected to the orientation determination unit and can transmit data to the tool control via an interface suitable for communication, wherein the orientation determination unit and/or the output unit is suitable for determining at least one control parameter, in particular a multitude of control parameters, after comparing the orientation data or the orientation-specific data to comparison variables, it being possible to transmit the at least one control parameter to the tool control for controlling the tool.

Abstract: An arc start control method in robot welding includes the steps of shorting a welding wire with a base metal, retracting a welding torch by a welding robot for taking the welding wire off the base metal to generate an initial arc, retracting the welding torch to a predetermined position with maintaining the initial arc maintained while applying an initial arc current smaller than a steady welding current during this initial arc period, and starting to feed the welding wire steadily and to supply the steady welding current so as to make a transition from the initial arc to a steady arc as well as starting to move the welding torch along a welding line. During a re-shorting prevention period which starts from a beginning of the initial arc period, a re-shorting prevention current which is larger than the initial arc current is applied in order to prevent re-shortening between the wire tip and the base metal right after the initial arc was generated. Thereafter, the initial arc current is applied.

Abstract: A method and test block for controlling weld penetration depth in a work piece are disclosed. The test block simulates a work piece relative to a welding process of the work piece. The test block includes a test welding path. The test welding path replicates a production welding path on a weld surface of the work piece. The test block includes a melt-thru surface that underlies the test welding path. The melt-thru surface is spaced apart from the test welding path by a spacing that decreases along a length of the test welding path. The spacing varies from more than a standard weld penetration depth to less than the standard weld penetration depth.

Abstract: The invention relates to a method for permanently interconnecting components from a heat-meltable metal material, using a robot-controlled welding unit for carrying out a hybrid welding process. According to the method, a high performance metal active gas welding process (high performance MAG) is carried out. A component (8) carrying out the high performance MAG welding process is carried along by the robot-controlled welding unit (2) to carry out the hybrid welding process, the GSMAW torch (3) which contributes to the hybrid welding process being guided so as to be dragged by the welding unit.

Abstract: A method to determine welding conditions includes relational expressions or tables about various parameters for setting welding conditions. The method can determine and display the recommended values for the welding conditions which are suitable for the information about the object to be welded and the information about the welding method set by the operator. The welding conditions include a welding current, a welding voltage, a wire feed speed, a welding speed, and a leg length. Furthermore, if the operator changes the recommended value for a welding condition to a new value, the method can determine new recommended values for the other welding conditions compatible with the new value and display the new recommended values.

Abstract: A method for determination of electrical variables of a welding circuit which is connected to an electrical power supply device and operable to provide either a welding current or a lesser pilot current, the method including the steps of (a) determining the resistance of the welding circuit and (b) determining the inductance of the welding circuit.

Abstract: A system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration devices each having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.

Abstract: Systems and methods for setting welding parameters are provided. For example, in certain embodiments, a method includes receiving an input relating to a change in a parameter of welding power of a welding system via a welding system interface. The method also includes displaying a graphical representation of an acceptable range of values for the parameter of the welding power on a display device of the welding system interface, wherein the acceptable range of values is based on other parameters of a welding process being performed by the welding system. The method further includes constraining subsequent manual inputs relating to changes in the parameter of the welding power to the acceptable range of values.

Abstract: In a method and device for performing welding, after the welding current reaches a first current value during a short circuit, the feeding of the welding wire is stopped, slowed down, or moved backward. As a result, the opening of a short circuit is urged to reduce the frequency at which welding is unnecessarily interrupted by an overcurrent protection function. This achieves high weld quality such as the absence of welding defects, and high production efficiency.

Abstract: An arc welding system and methods. The system is capable of monitoring variables during a welding process, according to wave shape states, and weighting the variables accordingly, detecting defects of a weld, diagnosing possible causes of the defects, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A welding system for welding with wire is disclosed that includes a torque motor in a wire feeder and a pull motor in a welding torch. A wire feed speed may be set by an operator at a power supply or on a wire feeder. Based upon calibration of the pull motor in the torch, upon startup of the welding operation, signals are provided to a pull motor and the torch in an open loop manner with respect to the speed of the pull motor, while the torque motor is driven to maintain a feed force on the welding wire to ensure that the pull motor has welding wire available for feeding. No other coordination is required between the torque motor and the pull motor.

Abstract: A weld monitoring and recording system and method monitors an ongoing welding operation and compares the welding current, the welding voltage, pre-heat/inter-pass temperature or other parameters from a previously qualified weld that are stored within a programmable device or computer. If the monitored parameters vary from the qualified parameters, then the weld is automatically interrupted until the operating parameters once again match the stored qualified parameters. A recorder can record different values related to the ongoing welding operation in order to provide documentation about the weld that can be viewed, printed, or downloaded.

Abstract: An arc welding control method for carrying out welding by generating an arc between a wire and a base material. The wire is fed at wire feed speed (Wf) of periodically repeating forward feeding and reverse feeding with predetermined frequency and amplitude from time point (100) at which start of the welding is instructed, or from a certain time point (101) after the start of the welding is instructed, and then the wire feed speed is changed to a constant speed. Since the wire feed speed is controlled by periodically repeating forward feeding and reverse feeding at the arc start, short-circuit can be opened regardless of the electromagnetic pinch force, and spatters, which are generated at the early stage of the arc start because a molten pool is not preset, can be reduced.