Abstract: A method and apparatus for welding that includes a power source and a wire feeder is disclosed. One or more sensors sense one or more welding conditions before the weld is initiated. A set up circuit is coupled to sensor, the power source, and the wire feeder. The set up circuit automatically sets up the welding machine in response to what the sensor senses. The sensor may be a wire sensor, including a diameter sensor and a material sensor, a gas sensor (if a source of gas is included) such as a cyclic voltametry gas microsensor, a workpiece thickness sensor such as a strain gauge or displacement sensor. Alternatively the sensor includes a bar code reader that reads a code on, for example, the spool of wire, an analog proximity detector, a plurality of proximity detectors, and a displacement sensor.

Abstract: An plasma cutter, including a power supply, a cutting torch (with a nozzle), a source of air and a valve, is disclosed. The cutting torch is connected to the two power source outputs (cathode and anode). Air is supplied to the nozzle through the valve from the air supply. In one position the valve allows air to flow from the air source to the nozzle. In a second position the valve prevents air from flowing from the air supply to the nozzle and also vents the nozzle and torch. The torch has a movable electrode and the nozzle is in a fixed position. The nozzle and electrode are each electrically connected to a different one of the power outputs. The electrode is biased (preferably by a spring) to be in contact with the nozzle. However, air flowing into the torch and electrode overcomes the bias and moves the electrode away from the nozzle. If the arc is absent and the user desires current, then the valve is moved to prevent air from flowing into the torch and to vent the torch.

Abstract: A method and apparatus for providing a welding current is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding. The welding current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and an auxiliary power controller that can receive a range of input voltage and provide a control power signal to the controller.

Abstract: A method and apparatus for induction heating includes a power supply, and a controller, and an induction head. The induction head includes a flexible coiled, such as one formed with Litz wire. The head also includes a thermal insulator, for disposing between the head and the workpiece. The insulator reflects heat back to the workpiece, protecting the coil, but is transparent to inductive (E-M) energy. The power supply is a variable output frequency power supply, such as one having a resonant tank, to adapt to the inductance of the head.

Abstract: A system for arc welding includes a welding power supply and a wire feeder. The wire feeder includes a dc wire feed motor and a dc wire feed power supply in electrical communication with the wire feed motor. A PTC thermistor is disposed electrically between the power supply and the wire feed motor. Current flows from the power supply, through the PTC thermistor, and then to the motor. Under normal current conditions the PTC thermistor allows current to be provided to the wire feed motor from the power supply, but under excessive current conditions the PTC thermistor inhibits current from being provided to the wire feed motor from the power supply. A diode is connected in anti-parallel with the motor. A pulse width modulation switch control current delivered to the motor. A normally open relay is closed when welding is to be performed to provide current to the motor, and a normally closed relay, connected in parallel with and shunting the motor, is opened when welding is to be performed.

Abstract: A power supply connector includes a cable receptacle, a front bulkhead insulator and a rear bulkhead insulator. The bulkhead insulators are mounted on the cable receptacle and the power supply chassis. At least one O ring is disposed between the front and rear bulkhead insulators, to seal out water. The front bulkhead insulator includes a stepped portion that mates with a stepped portion on the rear bulkhead insulator. The front bulkhead insulator provides an elongated path from the chassis to the cable receptacle. Also, an O ring is disposed between the cable receptacle and the front bulkhead insulator, to seal out water.

Abstract: A method and apparatus for plasma cutting includes a cutting power supply, preferably a buck converter, and a compressor. The cutting power supply provides power to a plasma torch, and the compressor provides air to the torch. The air compressor is integrated into the plasma cutter, and includes a compressor motor, preferably with a buck convertor power supply, or having the motor windings are part of the buck converter that is the cutting power supply. The motor is regulated regulator to a fixed setpoint or a user setpoint by a compressor regulator in response to a feedback signal, preferably a compressor motor voltage feedback signal. The compressor also turns the compressor on and/off in response to a trigger and/or cutting current feedback signal and has an on/off circuit responsive thereto in various alternatives.

Abstract: A method and apparatus for winding film includes haul-in rolls, a spindle, an airhorn, a kick-roll, and a belt or ropes to convey the film. A source of air creates an air curtain downstream of the spindle. The air curtain directs the leading edge of the film into the airhorn and over the spindle. A film guide located upstream of the airhorn guides a leading edge of the film back into its own nip. An air guide located between the film guide and the conveyor leading to the spindle prevents air from going back upstream of the airhorn. The guides are comprised of a non-stick material. Holes near the edge of guide allow air to exit the air horn, without perturbing the film where it tucks into its own nip. A static pinner may pin the leading edge of the film to the spindle. The spindle may have a winding surface tapered by less 0.03 inches per foot. The spindle has an air inlet, and outlet holes. The inlet area is greater than the hole area, by up to a 7:1 ratio.

Abstract: A method or apparatus for sub arc/tubular wire arc welding includes providing a first wire to a first welding arc and a first ac power signal to the first welding arc. The first ac power signal is a substantially constant voltage signal. A second wire may be provided to a second welding arc near the first welding arc, and a second ac power signal is then provided to the second arc. A phase relationship between the first and second ac power signals is selected from a plurality of at least three possible phase relationships. Preferably, the frequency and/or balance of at least one of the signals is selectable. Also, the output frequency is preferably controllable such that it can be more or less than the input frequency.

Abstract: A method and apparatus for wire feeding in an arc welding system includes a wire feed motor and a controller. The controller has an input circuit and an intermediate control signal. The input circuit includes a user selectable wire feed speed input, and the intermediate control signal is responsive to the user selectable wire feed speed input. The user selectable wire feed speed input includes a nonlinear potentiometer, that may be an arcuate, trimmed, potentiometer and provides either step or varying changes in the nonlinear first response, to produce at least two slopes or a varying slope. The intermediate control signal has a first response relative to the user selectable wire feed speed input. The wire feed speed has a second response relative to the intermediate control signal that is undesiredly nonlinear over a range. The wire feed speed has an overall response relative to the user selectable wire feed speed input.

Abstract: A power supply that receives an input voltage and provides output power is described. A method for selecting one of a plurality of input voltages by moving first and second links is also described. The power supply includes a housing and the links are inside the housing. The links configure the power supply to receive a selected input voltage from a number of input voltages, depending upon the position they are in. The links depend on one another. Indicators are connected to the links, and show for what input voltage the links are connected. The indicators are visible from outside the housing. The housing includes one or more windows through which the indicators are visible. The indicators are alpha-numeric characters or drawings. The links includes a circuit board with the indicators mounted thereon and a plug or a set of copper bars that are placed in either the first or second position.

Abstract: A power supply with an input protection circuit is disclosed. The protection circuit includes a thermistor that heats up if the power supply is mistakenly connected to an excessive input voltage. When the thermistor gets hot, its resistance increases, and isolates the down stream portion of the power supply from the input voltage. A relay in parallel with the thermistor is closed, thus shorting the thermistor, after a preset time if the input voltage had a proper magnitude.

Abstract: A method and apparatus for providing a welding output and an auxiliary output from a generator having a field winding, an auxiliary output winding and a welding output winding is disclosed. One or both of a welding output and an auxiliary output are detected, and feedback signals indicative of the presence or absence of one or both of a welding output and an auxiliary output are provided. A controller, preferably an electronic field controller includes an auxiliary output regulator enabled or disabled by the output detector feedback signal and a welding regulator enabled or disabled by the output detector feedback, such that one and only one of the auxiliary output regulator and welding regulator is enabled. The auxiliary output regulator is connected to an auxiliary output feedback circuit, thereby providing closed loop control, preferably with a CV output.

Abstract: A plasma arc cutting power supply, and method of providing plasma cutting power, is disclosed. It includes a source of power having, preferably an engine or transformer based power source, that provides a main power output and an auxiliary power output. A two-state configuration circuit is in electrical communication with the auxiliary power output. The auxiliary power output receives voltage of a first magnitude with a non-floating ground when the configuration circuit is in its first state. The auxiliary power output receives voltage of a second magnitude, preferably different than the first magnitude, with a floating ground, when the configuration circuit is in its second state. When a plasma cutting circuit is connected to the auxiliary power output the configuration circuit is set in its second state. The plasma cutting circuit includes at least one chopper. A safety circuit that disables the plasma output includes a GFI or optical isolator.

Abstract: A method and apparatus of anodizing a component, preferably aluminum, is disclosed. The component is placed in an electrolyte solution. A number of pulses are applied to the solution and component. Each pulse is formed by a pattern including having three magnitudes. The third magnitude is less, preferably substantially less, than the first and second magnitudes, and all three magnitudes are of the same polarity. The pulse pattern may include alternations between the first and second magnitudes, and following the alternations, the third magnitude. Other patterns may be provided. The solution is in a reaction chamber, along with at least a portion of the component. The fluid enters the reaction chamber from a transport chamber through a plurality of inlets directed toward the component, preferably at an angle of between 60 and 70 degrees. The inlet is preferably the cathode, and the component is the anode, whereby current flows between the cathode and the anode in another embodiment.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: A method and apparatus for providing welding power from an engine/generator driven welding power supply includes an engine and a generator. A welding power supply is connected to the generator output, and provides welding power. A controller controls the apparatus, and receives an RPM input signal indicative of the engine RPM, and a user selected magnitude input. The controller includes an output reduction circuit that reduces the magnitude of the welding power by a variable amount in the event the engine is likely to stall, so as to reduce the likelihood of a stall, but maintain sufficient power for a welding arc. The magnitude of the welding power is reduced by an amount responsive to the engine speed in the event that the engine RPM is less than an RPM threshold, and/or by an amount responsive to the user selectable setting in the event that the user selectable setting is greater than a threshold.

Abstract: A method and apparatus for welding include a source of power, a wire feeder and a controller. The controller sends control signals to the wire feeder and the source of power. The controller also has an adjustable arc control input, and the controller controls at least three welding parameters in response to the arc control input. The arc control input may be an arc width input, and the controller may simultaneously control at least three welding parameters to obtain a desired arc width. The at least three welding parameters may include at least three of peak welding current, background welding current, pulse width, and frequency and the arc control input may be a user-selectable input.

Abstract: A plastic bag making machine is disclosed, and includes a dancer assembly that receives film from which the bags are to be made. The film travels from the dancer assembly to a drum-in nip and then to a sealing drum. After the sealing drum, the film travels to a drum-out nip. Then the film travels to a device-in nip, vertically through a processing device, and then to a device-out nip. A controller is connected to and controls the drum-in nip, the drum-out nip, the device-in nip, the device out nip, the dancer assembly and the sealing drum (including the seal bars and/or the sealing blanket drives). The controller includes a memory in which at least one set of operating parameters used to control the machine is stored.

Abstract: A method and apparatus for welding is disclosed. The method includes sensing the status of a trigger between an on position and an off position. A system latch is set or released based on the trigger status and the latch status. The system latches on when the trigger is held for a predetermined time (and the latch was previously off). The latch is released when the trigger is pulled and released when the latch was previously on. When the latch is off, pulling the trigger turns the system on, and releasing the trigger before the predetermined time turns the system off. The latch may also be released when welding current drops below a threshold. The time might not start until after welding current is flowing. A welding wire feed speed control potentiometer on a torch is also disclosed. The range of the torch potentiometer is from a minimum to a value dependent on the control panel welding wire feed speed. A run-in wire feed speed control is also disclosed.