Abstract: Virtual reality arc welding systems that provide virtual reality simulations for training purposes. Virtual reality welding systems to aid in training welding students may provide a programmable processor-based subsystem, a rendering engine, an analysis engine, and recommended corrective actions based on virtual testing results.

Abstract: Embodiments of systems and methods to relate a human operator to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a welding helmet within a welding environment, and a triggering status indicating a triggering of an arc detection sensor of the welding helmet due to initiation of a welding arc. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source within the welding environment, and an activation status indicating an activation of the welding power source. The server computer is configured to match the welding power source to a human operator using the welding helmet based on at least the first data and the second data.

Abstract: Embodiments of arc plasma cutting torches are disclosed. In one embodiment, an eccentric plasma cutting torch includes an upper portion and a lower portion. The lower portion is angled on one side along a length ? which results from continuously smaller cross sections of the lower portion which are biased towards a non-angled side of the torch. As a result, a central axis of an electrode of the torch, used for cutting, is biased by an offset from a central axis of the upper portion towards the non-angled side of the torch. Such an offset allows for a torch tip region of the torch to get closer into otherwise difficult-to-access portions of workpieces for cutting. Furthermore, the overall dimensions of the torch are configured such that cooling elements within the torch dissipate enough heat to keep the torch in a stable operating condition during a cutting operation.

Abstract: Embodiments for performing manufacture processes are disclosed. In one embodiment, a system includes a tool to be used in a manufacture process on a workpiece. The system includes a robot having an arm. The arm has an attachment point and is configured to move the tool, when attached to the attachment point, in multiple degrees of freedom during the manufacture process. A robot controller of the robot controls the movement of the arm based on motion parameters to perform the manufacture process via the tool. The system includes a power source having power electronics to generate electrical output power, based on electrical input parameters, provided to the tool during the manufacture process. A power source controller of the power source is configured to communicate with the robot controller, allowing a path planner component to generate the motion parameters used to perform the manufacture process while avoiding robot collision conflicts.

Abstract: Embodiments of the present invention are directed to an air cooled cutting torch having improved performance. The torch comprises an improved electrode, where the electrode has at least one gas flow port to allow air flow to pass through the electrode to improve cooling and performance.

Abstract: Various systems and methods are provided that allow a weld sequencer to use a statistical analysis of generated reports to automatically determine weld parameter limits for the welds defined by various functions in a sequence file. For example, the weld sequencer can take reports generated for a specific type of part and statistically analyze the weld data included in the reports according to a set of analysis parameters provided by a user. The weld sequencer can use the statistical analysis to identify and remove outlier data and define a set of weld parameter limits based on the remaining data. The weld parameter limits can define a low limit and/or a high limit for one or more weld parameters associated with a function. The weld sequencer can then update the sequence file to include the weld parameter limits.

Abstract: A method providing a welding apparatus configured to supply a welding wire to a welding gun and a welding system implementing the same is described. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program, the program dynamically adjusting the amount of welding wire retraction based at least upon one of the following: welding are current, welding wire size, welding wire speed and burnback time. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire preferably does not extend (or minimally extends—or may be at least partially recessed within the tip) from the opening of the welding gun nozzle tip. The system and method also includes an ability to stop advancement or retraction of the wire to prevent damage.

Abstract: A spool wire storage device includes a cabinet body, a door for providing access to an interior of the cabinet body, and a plurality of U-shaped spooled wire storage trays mounted within the cabinet body. The U-shaped spooled wire storage trays include a U-shaped bottom shelf, and a U-shaped sidewall extending upward from the U-shaped bottom shelf. The U-shaped bottom shelf and the U-shaped sidewall form an open front portion of the storage tray extending between terminal ends of the U-shaped sidewall. The U-shaped bottom shelf declines from the open front portion rearward. A spool of wire is located in each of the plurality of U-shaped spooled wire storage trays. A base is located beneath the cabinet body. The base forms a first fork channel and a second fork channel configured to receive forklift forks.

Abstract: A mobile welding system that does not rely exclusively on a track to define the path of the welder.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: The invention described herein generally pertains to a system and method related to a semi-automatic or a manual welding operation and utilizing a member or a clamp to removeably secure a torch or a torch cable to a wire feeder. The member can include a first portion that is separated from a second portion, wherein a curved portion is in between the first portion and the second portion. The member can include an opening on the first portion that blocks a path of connect or disconnect with a portion of the torch or the torch cable. Further, the member can include an aperture on the second portion that is used to couple to a portion of the wire feeder with a fastener.

Abstract: A welding or cutting system is provided that uses welding cables between a wire feeder and a power supply for high-speed data communications between the wire feeder and the power supply. A system designed as discussed herein eliminates the need for voltage and/or current sense leads for communication arc voltages/currents detected at the welding operation.

Abstract: A welding assembly and method is described which includes a charging circuit and regulator coupled to an input power source; an energy storage element connected in parallel with the charging circuit and regulator to increase the weld current output, wherein the energy storage element is charged by the charging circuit and regulator; and a weld output controller connected in parallel with the energy storage element for controlling a welding arc between an electrode and a workpiece, wherein the weld output controller includes a forward converter/inverter including a series circuit of a primary winding of a transformer, and a switching element which is coupled to the energy storage element, and a rectifier smoothing circuit which rectifies and smoothes a voltage induced in a secondary winding of the transformer according to a switching operation of the switching element, wherein the rectifier smoothing circuit conducts during an ON period of the switching element.

Abstract: Embodiments for performing manufacture processes are disclosed. In one embodiment, a system includes a tool to be used in a manufacture process on a workpiece. The system includes a robot having an arm. The arm has an attachment point and is configured to move the tool, when attached to the attachment point, in multiple degrees of freedom during the manufacture process. A robot controller of the robot controls the movement of the arm based on motion parameters to perform the manufacture process via the tool. The system includes a power source having power electronics to generate electrical output power, based on electrical input parameters, provided to the tool during the manufacture process. A power source controller of the power source is configured to communicate with the robot controller, allowing a path planner component to generate the motion parameters used to perform the manufacture process while avoiding robot collision conflicts.

Abstract: The invention relates to an electric arc cutting or welding torch comprising a torch body and torch head to be assembled to or disassembled from the torch body, the torch body comprising a peripheral wall and an axial housing, the axial housing comprising an orifice for receipt of at least part of the torch head, an actuator which is mobile in translation in the axial housing, at least one blocking element which is fitted so as to be mobile on the peripheral wall, the blocking element and the torch head each comprising reciprocal engagement means, the actuator being configured to maintain the blocking element spaced relative to the peripheral wall, the actuator also being configured to be displaced in the axial housing when the torch head is inserted in the orifice.

Abstract: A system and method to make a welder aware of contact tip-to-work distance (CTWD) during a welding process. One or both of welding output current and wire feed speed is sampled in real time during the welding process. The actual CTWD is determined in real time based on at least one or both of the sampled welding output current and wire feed speed. The actual CTWD may be compared to a target CTWD in real time, where the target CTWD represents an estimated or desired CTWD for the welding process. A deviation parameter may be generated based on the comparing. An indication of the deviation parameter or the actual CTWD may be provided to a welder performing the welding process as feedback, allowing the welder to adjust the actual CTWD to better match the target CTWD in real time during the welding process.

Abstract: A system and a method for tracking and analyzing welding activity. Dynamic spatial properties of a welding tool are sensed during a welding process producing a weld. The sensed dynamic spatial properties are tracked over time and the tracked dynamic spatial properties are captured as tracked data during the welding process. The tracked data is analyzed to determine performance characteristics of a welder performing the welding process and quality characteristics of a weld produced by the welding process. The performance characteristics and the quality characteristics may be subsequently reviewed.