Abstract: A real-time virtual reality welding system including a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of displaying the simulated weld puddle on the display device in real-time.

Abstract: Embodiments of the present invention are engine drive welding and/or cutting systems which optimize the utilization of engine drive systems, including hybrid engine drive systems. Embodiments include modular systems which allow for the remote utilization of a battery powered module which can be separated from an engine drive generator power supply. Other embodiments include engine drive power supplies that can communicate with a load coupled to the power supply, such as welders, cutters and wire feeders to determine an optimum operational level. Further embodiments include engine drive power supplies that can be coupled together to optimize fuel and system usage.

Abstract: A device for arc welding with fusible wire including a device for setting the wire speed and a device for selecting a metal transfer rate type, the device for setting the wire speed being maneuverable by the hands or fingers of an operator. The device for selecting a metal transfer rate type cooperate with the device for setting the wire speed in such a way as to allow the operator to set the wire speed by maneuvering the device for setting the wire speed and to automatically select, on the basis of the wire speed setting, a metal transfer rate type.

Abstract: A learning management system (LMS) for tracking student progress as students learn how to weld in a real-time, simulated, virtual reality welding training environment. Systems and methods to help welding instructors and students manage the data associated with instruction and learning in a virtual reality welding environment are provided. Welding student training data generated by students while using virtual reality welding systems is stored in a centralized database. The centralized database is accessible by a user (e.g., a welding instructor) using a personal computer having a learning management software application (LMSA) installed thereon. The LMSA is configured to allow the user to access at least a portion of the student training data for one or more of viewing, analysis, grading, and reporting.

Abstract: A contact tip for hot-wire welder is provided that are adapted to operate in deep and narrow recessed gaps within a work piece. Contact tips in accordance with the current invention provide for an assembly having a body portion with a cavity and an extension portion which is inserted into the cavity. The extension portion is non-electrically conductive and allows the contact tip assembly to reach into deep, narrow grooves without worry of shorting the contact tip of the consumable.

Abstract: An arc welding system includes a welding torch, an electrode, and a power supply having a switching-type power converter connected to the torch. A parallel state-based controller is connected to the power converter and provides a waveform control signal thereto for controlling its operations. The controller generates a motion control signal for controlling movements of the electrode and/or the torch. A sensor senses welding voltage or welding current. A memory stores a welding state table comprising sequential control states, and stores a motion control system state table comprising further sequential control states. The welding waveform is defined in the welding state table. The controller controls the operations of the power converter through the waveform control signal according to the welding state table, simultaneously adjusting the motion control signal according to the motion control system state table. The controller transitions between control states according to the signal received from the sensor.

Abstract: A welding system comprises a welding power source that provides an alternating current in a selected wave form having a set of positive and negative portions, the negative portion consisting of a peak, tailout, and background phase, and the positive portion consisting of a peak, tailout, and background; wherein the power source provides an upward ramping current during the pinch and detachment phase, switches to an electrode negative current during the negative peak, tailout, and background phases, and switches to a subsequent electrode positive portion; wherein, the positive portion may repeat prior to the next shorting event.

Abstract: The invention described herein generally pertains to a system and method related to reducing magnetic arc blow during a welding operation performed by a welding system. In accordance with one embodiment of the invention, a welding system including a waveform generator generates a waveform that is switched from a positive current to a negative current, while passing through zero, in a step-wise fashion to resist the magnetic field within the material (e.g., the workpiece). In accordance of another embodiment of the invention, the welding system includes a nickel flux cord welding wire.

Abstract: A power source for an implement used to perform a welding or cutting operation, the power source including an engine component including a generator and a rectifier electrically connected to the generator and adapted to convert alternating current provided by the generator to a direct current, the engine component being switchable between an on condition and an off condition; at least one battery, wherein the engine component and at least one battery are electrically connected to a chopper bus; and a controller in communication with the generator, chopper bus, operation chopper, and the charging switch; an auxiliary power converter including at least one of a DC to AC and a DC to DC converter, the auxiliary power converter being electrically connected to the operation chopper and the at least one battery.

Abstract: A power source system including plural power sources, wherein each of the plural power sources is adapted to provide a configurable power output to an implement, and wherein each of the plural power sources has an onboard controller; a central controller that is remote from the plural power sources; the central controller being in communication with respective onboard controllers via one or more networks, the central controller being adapted to communicate a signal to at least one onboard controller to selectively alter an operating condition of an associated power source.

Abstract: A cutting system including a plasma arc torch having an electrode, nozzle, and a gas conduit through which gas is transferred to a torch tip. The torch includes at least one of a sensor and a set circuit, where the set circuit stores a parameter related to the torch. The system also includes a power supply outputting a cutting waveform to the electrode via an electrical connector to initiate a working arc. The working arc creates a plasma arc using the gas. The system further includes a controller that controls an output of the power supply and a feeding of the gas through the gas conduit based upon input from a user input device positioned on at least one of the torch and the power supply. The controller monitors at least one usage parameter. The system additionally includes a memory device that is coupled to the controller. The memory device stores data related to the at least one usage parameter.

Abstract: A flow-through sampling apparatus for sampling a bulk solid mixture includes a main body forming an opening. A screen is located in the opening and forms a plurality of sample zones within the main body. The apparatus further includes a first slide door that is movable above the screen so as to close one side of the opening. Further, the apparatus includes a second slide door that is movable below the screen so as to close the other side of the opening.

Abstract: In one embodiment of an enclosure device, a camera casing and light source casing are secured to a plate frame, and the enclosure device is configured to be mounted to an arm, such as a robotic welding arm. A shutter mounting arm may also be secured to the plate frame. A flap may be pivotally mounted to the distal end of the shutter mounting arm, such that the flap may be actuated between a first and second position by an actuator cooperatively engaged with the flap. The first position may be defined as to protect a camera lens positioned in the camera casing and a light source lens positioned in the light source casing. The second position may be defined as to not obscure a line-of-sight from either the light source and/or the camera to the work piece on the arm.

Abstract: A workpiece positioning system integrated with a fume extraction device, the system including a movable work surface assembly including at least one work surface; at least one divider extending upward from the at least one work surface dividing the at least one work surface into a plurality of work zones in which a welding operation is performed, the divider including a collection assembly comprising a first ventilation port on a first side of the divider opening toward a first work zone of the plurality of work zones and a second ventilation port on a second side of the divider opening toward a second work zone of the plurality of work zones formed by the divider; wherein at least one of the first and second ventilation ports are selectively placed in fluid communication with the fume extraction device to draw fume from at least one of the plurality of work zones.

Abstract: A plasma torch system and method is provided, in which the system utilizes a number of pressure sensors throughout the system and the torch to detect the flow/pressure of shield and plasma gas during operation. The detected pressures are used by the system to dynamically control the system pressures to optimize the cutting operation.

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 intelligent connections to web sites on the internet, overlays of ideal weld puddles, recommended corrective actions based on virtual testing results, simulations of virtual environments with safety hazards, and simulations of relationships between improperly set welding parameters and weld defects and discontinuities.

Abstract: A self-contained welding power supply capable of, upon termination of welding operation, automatically setting a control signal for auxiliary power is provided. The power supply comprises an engine, a generator driven by the engine, and an excitation system that controls power output of the generator. The excitation system includes an output controller and a DC controller. The output controller includes circuitry that generates a field voltage control signal to be sent to the DC controller to regulate DC power going to field windings of the generator. Upon termination of the welding operation, the field voltage control signal is automatically set to a value appropriate for the auxiliary system operation.

Abstract: A system and method is provided for monitoring and displaying real time information regarding the inductance of the welding circuit, such that a user can monitor the performance of a power supply to determine if the system inductance is adversely affecting the operation of the power supply, and where the system can change the output signal based on the detected system inductance.

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: A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.