Abstract: Embodiments of the present invention are directed to a combustion engine power generation device, such as an engine driven welder, which utilizes a first battery for engine start and providing operational power when the system is off, and a second high storage battery to provide all operational power so long as the second battery has the stored energy to supply the needed power. In an embodiment, the first battery is a lead acid battery and the second battery is a lithium ion battery.

Abstract: An arc welding system includes a welding power supply. An auxiliary power supply supplies electrical energy to an auxiliary load. An engine-generator is connected to the welding power supply and auxiliary power supply. An engine starting battery is connected to the auxiliary power supply to supply electrical energy thereto during starting of the engine-generator. An auxiliary load sensor is configured to detect a presence of an electrical load on the auxiliary power supply. A speed sensor is configured to sense a speed of the engine-generator. A controller is configured to receive a signal indicating presence of the electrical load on the auxiliary power supply and a signal corresponding to speed of the engine-generator. When presence of the electrical load on the auxiliary power supply is detected, the controller starts the engine-generator, and after the engine-generator has reached a predetermined speed, switches the auxiliary power supply from the battery to the engine-generator.

Abstract: Embodiments of welding systems are disclosed. In one embodiment, a welding power source includes a welding output connector and a battery output connector. Power electronics of the welding power source provide welding power at the welding output connector or battery power at the battery output connector. A current sensor senses when an electric current is flowing through a cable connected to the welding output connector or the battery output connector and outputs a voltage to the controller of the welding power source that is indicative of the electric current as sensed. The controller of the welding power source includes safety logic that determines when an unsafe condition of the welding power source exists based on at least the voltage from the current sensor.

Abstract: A welding or cutting device includes an internal combustion engine coupled to a generator for generating electrical power. A welding or cutting power supply is powered by the generator. The welding or cutting power supply supplies a welding or cutting output signal. An auxiliary outlet circuit is configured to receive power from the generator. The auxiliary outlet circuit includes at least one auxiliary load outlet. A controller controls an engine speed of the internal combustion engine. The controller is configured to determine an anticipated load on the generator to be supplied through the auxiliary load outlet, based on a no load condition of the auxiliary load outlet, and adjust an idle speed of the engine based on the anticipated load. The controller is further configured to subsequently increase the engine speed, from the idle speed to an auxiliary load speed, when the generator supplies power through the auxiliary load outlet.

Abstract: The invention described herein generally pertains to a system and method related to an engine driven welding device that includes a first brushless generator component configured to produce a first electrical current for use with a welding operation and a second brushless generator component configured to produce a second electrical current for use as auxiliary power. The first brushless generator component can be a permanent magnet generator and the second brushless generator component can be an asynchronous generator, each being coupled to a shaft of an engine within the engine driven welding device. A portion of the first electrical current produced can be fed into the second brushless generator component to act as an exciter, wherein the frequency of the portion of the first electrical current can be matched to the frequency of the second brushless generator component.

Abstract: Embodiments of the present invention are directed to a combustion engine power generation device, such as an engine driven welder, which utilizes a first battery for engine start and providing operational power when the system is off, and a second high storage battery to provide all operational power so long as the second battery has the stored energy to supply the needed power. In an embodiment, the first battery is a lead acid battery and the second battery is a lithium ion battery.

Abstract: An arc welding system includes a welding power supply. An auxiliary power supply supplies electrical energy to an auxiliary load. An engine-generator is connected to the welding power supply and auxiliary power supply. An engine starting battery is connected to the auxiliary power supply to supply electrical energy thereto during starting of the engine-generator. An auxiliary load sensor is configured to detect a presence of an electrical load on the auxiliary power supply. A speed sensor is configured to sense a speed of the engine-generator. A controller is configured to receive a signal indicating presence of the electrical load on the auxiliary power supply and a signal corresponding to speed of the engine-generator. When presence of the electrical load on the auxiliary power supply is detected, the controller starts the engine-generator, and after the engine-generator has reached a predetermined speed, switches the auxiliary power supply from the battery to the engine-generator.

Abstract: An engine welder having a single rotor and a single stator, and methods of distributing electrical power capacity of the engine welder to various welding windings and auxiliary windings of the engine welder. The single rotor is driven at saturation current and independent control of the welding outputs is accomplished on the stator side of the engine welder. Means for supplying the full electrical power capacity of the engine welder to a single stator welding winding are provided. Furthermore, means for distributing the electrical power capacity of the engine welder between welding windings and/or auxiliary windings of the single stator are provided.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism, a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism, a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism, a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism, a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A wire drive system includes a wire feed motor for feeding welding wire in a continuous welding process. The wire drive system further includes a controller connected to the wire feed motor for driving the motor responsive to a command signal. The controller is capable of detecting the source of power from which the wire feed motor is driven wherein a first possible source of power is taken from the welding arc and wherein a second possible source of power is taken from the welding power supply.

Abstract: A welding power supply includes a switching type power converter. A welding electrode is connected to the power converter to receive electrical energy therefrom and produce an electric arc. An engine-generator is connected to the welding power supply to supply electrical energy for producing the arc. The engine-generator comprises a plurality of armature windings, and a field winding. A battery is connected to the welding power supply to simultaneously supply further electrical energy for producing the arc, and to receive electrical energy from the engine-generator through the power supply to recharge the battery. A sensor senses battery voltage and/or current, and outputs a signal during recharging corresponding to the battery voltage and/or current. A field controller is connected to the field winding and to the sensor. The field controller receives the signal from the sensor and automatically adjusts a level of current flow through the field winding during recharging based on the signal from the sensor.

Abstract: A wire feeder for an electric arc welder comprising feed rolls driven by an electric motor for moving a welding wire toward a workpiece for an arc welding process. The motor is rotated at a speed determined by a WFS signal from a controller when energized by actuation of a start switch, a switch network has a first condition allowing the motor to operate at the speed determined by the WFS signal and a second override condition forcing the motor to rotate at a fixed lower speed, a toggle circuit with a first position to shift the switch network into the second condition upon actuation of the motor start switch and a second position to shift the switch network to the first condition upon receipt of a toggle signal, and a device to create the toggle signal when the load current to the motor exceeds a given value.

Abstract: An engine welder having a single rotor and a single stator, and methods of distributing electrical power capacity of the engine welder to various welding windings and auxiliary windings of the engine welder. The single rotor is driven at saturation current and independent control of the welding outputs is accomplished on the stator side of the engine welder. Means for supplying the full electrical power capacity of the engine welder to a single stator welding winding are provided. Furthermore, means for distributing the electrical power capacity of the engine welder between welding windings and/or auxiliary windings of the single stator are provided.

Abstract: A wire drive system includes a wire feed motor for feeding welding wire in a continuous welding process. The wire drive system further includes a controller connected to the wire feed motor for driving the motor responsive to a command signal. The controller is capable of detecting the source of power from which the wire feed motor is driven wherein a first possible source of power is taken from the welding arc and wherein a second possible source of power is taken from the welding power supply.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: An automatic wire feed adjuster, including a feeding mechanism including a pair of rollers that feeds a wire therebetween, a tension controller that adjusts a tension between the pair of rollers, a wire speed sensor that measures a fed speed of the wire after exiting the feeding mechanism, and a control circuit that compares a driven speed of the wire with the fed speed of the wire, and that decides whether to instruct the tension controller to adjust the tension between the pair of rollers.