Abstract: A system and method for a variable hot start of a welding-type device is disclosed. The variable hot start includes determining at least one of a plurality of parameters of a welding-type device including a desired V/A output for a welding-type process. The variable hot start process also includes selecting a startup V/A output greater than the desired V/A output based on the desired V/A output and selecting a duration of a hot start period based on the at least one of the plurality of parameters. A welding-type process is then hot started over the selected duration of the hot start period.

Abstract: A multifunction meter and method for monitoring a welding-type device is disclosed. The multifunction meter has a single display unit, a first input configured to receive feedback from an engine, and a second input configured to receive feedback from a power converter. The engine is configured to deliver power to the power converter which is configured to deliver a welding-type power to a welding-type apparatus. A processing unit is connected to the single display unit, the first input, and the second input, and processes the feedback from the engine and the feedback from the power converter and displays data indicative of engine operation and power output of the power converter on the single display unit.

Abstract: A method for reducing spatter in the short-circuit transfer gas shielded arc welding is disclosed. In this method, the resistance changing rate or the impedance changing rate of the welding circuit loop is detected for estimating the diameter of the short-circuit liquid bridge. When the diameter of the short-circuit liquid bridge shrinks to the preset value, the short-circuit bridge current is bypassed or shunted by the current closed loop feedback bypass control, and the current is decreased to a very low level rapidly and maintained this level until the bridge is broken, which results in a gentle and smooth drop transfer in a low current level condition, so as to avoid the mass spatter. Furthermore, a system for performing the method has also been disclosed.

Abstract: In a case where a motor 3 is stopped upon completion of welding, a motor stop can be effected irrespective of the length of control lines by disposing a first motor stop means 5a or a second motor stop means 5b in a feeding means 2.

Abstract: A contact tip for a welding gun having a central passage for a welding wire moving in a given direction toward a workpiece and receiving a welding signal by contact of the wire with the tip. The passage has an innermost end, an outermost exit end and a length of at least 1.5 inches and an opening in the contact tip intersects the passage so a pressure block slidably mounted in the opening is biased toward the wire by a spring around the contact tip urging the block against the wire. This tip is dimensioned and constructed to perform pulse welding by a relatively ductile aluminum wire.

Abstract: A method and apparatus for providing welding power with an arc-width control is disclosed. The power supply includes a power circuit that provides a welding output characterized by a plurality of welding output parameters, and the power circuit receives at least one control input. A controller provides control signals to the power circuit. The controller receives user inputs for arc width and wire feed speed. The controller has an arc width control module that provides control signals that adjust one or more welding output parameters. The adjustment has a gain responsive to the wire feed speed input, such that there are at least three gains over a range of possible wire feed speeds, in one embodiment. The arc width control module provides control signals that adjust at least five welding output parameters in response to the wire feed speed input and the arc-width control input, in another embodiment.

Abstract: A method for simultaneously brazing adjacent conductor joints comprises the steps of arranging at least two pair of conductor joints in a row placing a brazing compound between the pairs of joints desired to be electrically connected placing a conductive spacer between the pairs not to be brazed and passing an electrical current through the row of conductors until the brazing compound melts joining the conductor joints. The spacer can then be removed thereby maintaining the proper spacing between the pairs of brazed conductor joints. The multiple rows of conductor joints can be arranged adjacent one another so that they can be moved between brazing electrodes sequentially thereby allowing a continuous brazing operation of multiple rows of conductor joints. The brazing compound may be a continuous ribbon of brazing compound which extends between the multiple rows of conductor joints.

Abstract: The invention relates to a welding method involving the use of a non-fusing electrode (12) according to which the electrode (12) is provided with power from a power source once the arc (11) between the electrode (12) and the workpieces (13, 14) to be joined has been ignited. The invention also relates to a tack welding method. The aim of the invention is to improve the quality of the weld seam in the starting phase of the welding process. To this end, the invention provides that before the actual welding process, a start program (22) is performed without the introduction of a filler material during which the electrode (12) is supplied with pulsed power in the form of current or voltage pulses over a presettable length of time (23) whereby causing the liquid molten bath to oscillate or vibrate, and that after the execution of the start program (22), the actual welding process is carried out during which the electrode (12) is preferably supplied with constant power.

Abstract: The invention originates in the field of resistance welding technology, among other means by means of welding robots 1, for use in roll seam welding, projection welding or spot welding, and has to do with accommodating components for operation inside the housing 2 of the welding tongs. Taking the demands in terms of weight into account, the object of the invention is to achieve the most effective possible utilization of space for the housing 2 of the welding tongs carried by the welding robot. The housing 2 of the welding tongs is given a module 3 for this purpose. This module 3 includes modular components that are relevant to performing the welding process that is monitored by the welding controller.

Abstract: The present invention includes a system and method of controlling a remotely located welding-type power source. A communications system includes a user interface to accept a user input at a portable location and a gas purging device to systematically purge pressurized gas from a gas line connecting the portable location to a remote location based on the user input. The communications system also includes a sensor to sense pressure changes in the gas line at the remote location and a processor configured to convert the sensed pressure changes to a representation of the user input.

Abstract: A method for estimating weld nugget diameter includes receiving current and voltage inputs, a time input, and a force input. In certain embodiments, the method also uses other weld parameters including type of material, type of stack, stack thickness, applied force, preheat current, RMS value of weld current, weld level, and weld time. The method further determines a resistance curve based on the current and voltage inputs, and time input. It also derives parameters from the resistance curve, and determines a weld nugget diameter estimate based on both resistance parameters.

Abstract: An arc welding torch control system providing remotely selectable control over welding wire feed rate and welding current without discontinuing use of the welding device. A torch mounted three position switch provides for selection of variable wire feed rate with constant preselected current control, variable current control with a preselected constant wire feed rate, or simultaneous variation of both parameters over a given preselected range. Control of the selection and parameter range control is remotely presented to the welding operator by use of torch mounted controls or by remote controls co-located in the immediate location of with the welding torch so that the operator can manipulate the rate of the selected parameter by foot or otherwise without the need to discontinue the welding operation.

Abstract: The invention includes means for, when welding a crater in a welding termination portion, moving a torch in a direction allowing the whole of the torch to part apart from a molten pool and, therefore, the invention can prevent all welding wires from coming into contact with the molten pool. Also, the invention can check not only the crater-welded welding wire but also all of the remaining welding wires for deposition and, if there is detected a deposited wire, can energize the deposition detected wire again to thereby be able to remove the deposition of the wire.

Abstract: A device to control operation of a power source for an electric arc welder comprising an oscillator for inducing a high frequency voltage into a series circuit including the welding gap, a detector tuned to the high frequency for sensing the level of current in the series circuit at the high frequency and an output circuit to create a start signal when the received signal level exceeds a given value representing a resistance in said gap below a given amount.

Abstract: In accordance with an AC pulse arc welding method, a periodic welding current is applied, that includes, for a pulse cycle, negative current in electrode negative polarity and positive current in electrode positive polarity. Then, a negative current rate is set by a negative current rate setting value, where the negative current rate represents the ratio of the negative current to the welding current for the pulse cycle. Then, a feeding speed of welding wire as a consumable electrode is set by a feeding speed setting value. The method further includes: setting an average of the welding current by a welding current setting value; and performing automatic calculation of the feeding speed setting value by using a predetermined conversion function based on input of the welding current setting value and the negative current rate setting value.

Abstract: A method and apparatus for providing welding type power 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, cutting or induction heating. The welding type current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and a controller power supply can also receive a range of input voltages and provide a control power signal to the controller, and a voltage independent of the input voltage.

Abstract: A welding system comprises a combined torch that includes a consumable electrode and a non-consumable electrode positioned so that their respective axes form an acute angle and so that arcs initiated from the electrodes intersect a workpiece plane to define an impingement point distance D, and a magnetic mechanism coupled to the torch and used for controlling the distance D during welding. The magnetic mechanism may be a magnetic shield inserted between the electrodes, or a separate magnetic device, e.g. a permanent magnet or electromagnet.

Abstract: A welding head which can easily move the torch portion of the welding head in the circumferential direction and the vertical moving direction of the outer circumference of the to-be-welded tubes even in a narrow gap, includes a torch rotating ring that rotates on the outer circumferences of the tubes by matching with the central axis of the to-be-welded tubes and a torch vertical moving ring disposed concentrically with the ring inside the ring, provided with a torch base for supporting a torch on the front ends, a first gear group for driving and rotating the ring around the tubes, a second gear group that is disposed in parallel to the first gear group and drives and rotates the ring around the tubes, a drive shaft for driving the two gear groups, and a torch rotating motor for driving the drive shaft, and a third gear group that can drive the ring while rotating it in the same direction as or in reverse to that of the ring at a speed equal to or higher or lower than that of the first gear group for rotatin

Abstract: Methods of controlling an arc welding shop. In the shop, several welding torches are used and each torch is supplied with consumable wire. The wire moves at a wire speed and is subjected to an electrical current. For each torch, either an average wire speed or an average electrical current, as measured over a fixed time period, is determined by a sensor. These values then allow productivity parameters to be selected for the torches. Productivity parameters include the duty factor, the deposition rate, the average duty factor, and the average deposition rate.

Abstract: The invention relates to a multi-functional remote controller (27) for a welding apparatus and a welding current source, which remote controller can be connected to the welding apparatus and the welding current source by at least one line, the remote controller (27) having setting elements and switching elements and at least one display unit. The remote controller (27) has a memory, in particular a memory card, and at least one additional interface, in particular a USB terminal, and the various parameters, functions and/or operating modes are set and edited by a menu-driven system.