Abstract: A configuration and method for straightening a wire as the wire pays off from a bulk package. A bulk package hat is configured to be positioned over an opened bulk package containing wire bent in a helix shape. A bearing assembly is mounted inside the bulk package hat at a position where the wire exits the bulk package hat as the wire pays off from the bulk package. A wire straightening device has a plurality of rollers and only one single plane of straightening, and is configured to apply a counter bend to the wire as the wire pays off from the bulk package through the wire straightening device. The wire straightening device is operatively connected to the bearing assembly at an angle inside the bulk package hat. The bearing assembly and the single plane of straightening rotate, continually realigning with a current direction of the wire as it pays off.

Abstract: A method of correcting angles of a welding torch positioned by a user while training a robot of a robotic welding system is provided. Weldment depth data of a weldment and a corresponding weld seam is acquired and 3D point cloud data is generated. 3D plane and intersection data is generated from the 3D point cloud data, representing the weldment and weld seam. User-placed 3D torch position and orientation data for a recorded weld point along the weld seam is imported. A torch push angle and a torch work angle are calculated for the recorded weld point, with respect to the weldment and weld seam, based on the user-placed torch position and orientation data and the 3D plane and intersection data. The torch push angle and the torch work angle are corrected for the recorded weld point based on pre-stored ideal angles for the weld seam.

Abstract: A system and method for submerged arc welding. The system advances a consumable welding electrode toward a workpiece, and then stops the advancement when the consumable electrode makes contact with the workpiece. The system provides a preheating current level through the consumable welding electrode proximate the workpiece while the consumable welding electrode is in contact with the workpiece during a preheating period of time to preheat the portion of the consumable welding electrode without establishing an arc. The system then retracts the consumable welding electrode from the workpiece and increases the preheating current level to a welding current level over an arc establishment period of time to establish an arc between the consumable welding electrode and the workpiece. The system then begins to form a weld by advancing the consumable welding electrode toward the workpiece again, resulting in melting the consumable welding electrode and depositing molten metal onto the workpiece.

Abstract: A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.

Abstract: A regulating valve device for a fluid cylinder includes a shut off valve having a ball tappet that actuates the shut off valve. A lever has a cam surface that interacts with the ball tappet as the lever is rotated to translate the ball tappet linearly and actuate the shut off valve. The lever is rotatable from a first valve closed position through a valve open position to a second valve closed position such that the valve open position is intermediate of the first and second valve closed positions. A pressure or flow regulating valve is downstream of the shut off valve. A handwheel is operatively connected to the pressure or flow regulating valve to adjust an outlet pressure of the pressure or flow regulating valve. The handwheel has an axis of operation that is offset from a longitudinal axis of the fluid cylinder by an acute angle.

Abstract: An embodiment includes a robotic welding system for generating a motion program, having a programmable robot controller of a robot having a computer processor and a computer memory. The programmable robot controller is configured to digitally record, in the computer memory, a plurality of spatial points along an operator path in a 3D space taken by a calibrated tool center point (TCP) of the robot as an operator manually moves a robot arm of the robot along the operator path from a start point to a destination point within the 3D space. The programmable robot controller is also configured to identify and eliminate extraneous spatial points from the plurality of spatial points as digitally recorded, leaving a subset of the plurality of spatial points as digitally recorded, where the extraneous spatial points are a result of extraneous movements of the robot arm by the operator.

Abstract: An arc welding system providing improved molten metal droplet transfer. The system includes a welding power source having a welding power supply, a welding waveform generator, and a controller. Two fluxed cored welding wire electrodes are connected to the power source and are powered by the same welding output voltage and current produced by the power source. A feedback circuit is connected to the power source to provide an adaptive response to maintain an average welding output voltage. The controller controls the waveform generator and the power supply to superimpose welding current pulses onto a welding waveform of a CV flux cored arc welding process, that uses CO2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process. The current pulses are superimposed in time to form molten metal droplets between ends of the two electrodes during the modified welding process.

Abstract: A plasma cutting system includes a power supply that outputs first and second plasma cutting currents. A torch is connected to the power supply and includes a first cathode that receives the first plasma cutting current, a first electrode and swirl ring, a second cathode that receives the second plasma cutting current, and a second electrode and swirl ring. The torch simultaneously generates a first and second plasma arcs from the electrodes. A gas controller is configured to separately control a flow of a first plasma gas to the first swirl ring and a flow of a second plasma gas flow to the second swirl ring. A torch actuator moves the torch during cutting, and includes a motor having a hollow shaft rotor for rotating the torch during cutting. A motion controller is operatively connected to the torch actuator to control movements of the torch during cutting.