Abstract: A method and apparatus for providing welding type power includes receiving input power and pulse width modulating a first forward converter and a second forward converter so that they operate as a pulse width modulated double forward converter to provide a welding type output. A phase relationship between the first forward converter and a second forward converter is selected from at least two available phase relationships using a controller. The controller includes a pwm module, and the pwm module includes a phase relationship module. The at least two available phase relationships are at least two of variable phase shifting, fixed phase staggering and locked in phase. The selected phase relationship is maintained over a predetermined range of outputs.

Abstract: A welding-type power supply includes a controller, a preregulator, a preregulator bus, and an output converter. The controller has a preregulator control output and an output converter control output. The preregulator receives a range of inputs voltages as a power input, and receives the preregulator control output as a control input, and provides a preregulator power output signal. The preregulator includes a plurality of stacked boost circuits. The preregulator bus receives the preregulator output signal. The output converter receives the preregulator bus as a power signal and receives the output converter control output as a control input. The output converter provides a welding type power output, and includes at least one stacked inverter circuit.

Abstract: An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power, and to output the welding-type power via a welding-type circuit; a temperature sensor configured to measure a temperature of at least one component of the welding-type power supply; and stray current detection circuitry configured to detect stray welding-type current based on the measured temperature of the at least one component.

Abstract: Welding power supplies with regulated background power supplies are disclosed. An example welding power supply includes a background circuit, which comprises: a power supply capable of outputting a first power output; an energy storage device configured to be charged by the first power output to a programmable first voltage level; a fast acting switch coupled to the energy storage device and configured to switch to restrict or allow voltage discharge from the energy storage device to welding electrodes; and a control circuit configured to selectively activate the power supply to output the first power output when the energy storage device is not charged to the regulated first voltage level, and further configured to actuate the fast acting switch to allow voltage discharge of the energy storage device from the regulated first voltage level to a controlled second voltage level when a transient high voltage event is detected.

Abstract: A welding system including a welding power source including power conversion circuitry adapted to receive primary power and to convert the primary power to a weld power output for use in a welding operation and a controller communicatively coupled to the welding power source are provided. The controller is adapted to determine a statistical signature of at least one parameter of a welding process and to utilize the statistical signature to determine at least one of an electrode type, an electrode diameter, and a shielding gas type during the welding operation.

Abstract: A method and apparatus for TIG welding and starting a TIG welding process includes limiting the pulse width of a power circuit when a TIG start is being performed, and monitoring for the creation of a welding arc. After the welding arc has been detected the limiting of the pulse width is ended.

Abstract: Apparatus, systems, and/or methods are disclosed relating to a welding-type power supply with a pre-regulator circuit configured to provide a pre-regulated direct current (DC) bus at two or more voltage levels, responsive to various operating conditions. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage at one voltage level for certain input line voltages, weld processes, and/or target weld output levels, and at another voltage level for other input line voltages, weld processes, and/or target weld output levels. In some examples, the pre-regulator circuit may be configured to provide a pre-regulated DC bus voltage for certain input line voltages, weld processes, and/or target weld output levels and an unregulated DC bus voltage at other input line voltages, weld processes, and/or target weld output levels.

Abstract: A low voltage system and method for servicing welding equipment including a service tool that may provide a low voltage power source to the welding equipment, enabling the welding equipment to be tested in a low voltage mode of operation. The service tool may also run various test sequences on the welding equipment operating in a low voltage mode of operation to troubleshoot and diagnose any issues with the circuitry of the welding equipment.

Abstract: A method and apparatus for TIG welding and starting a TIG welding process includes limiting the pulse width of a power circuit when a TIG start is being performed, and monitoring for the creation of a welding arc. After the welding arc has been detected the limiting of the pulse width is ended.

Abstract: A welding-type power supply includes a controller, bus (that can, but need not be preregulated), and an output converter. The controller has a preregulator control output and an output converter control output. The controller may receive bus feedback indicative of a plurality of bus voltages. A bus voltage balancing module in the converter includes a scaled correction module responsive to the bus feedback signal, and the converter control output is responsive to the bus voltage balancing module. The controller may receive load feedback indicative of a load output, have a bus voltage balancing module that includes a load proportional gain module responsive to the load.

Abstract: A welding-type power system that provides balanced split phase AC power or three phase AC power from a DC power bus that includes a power supply, a DC power bus, inverters, and a balancing circuit. The inverters and the balancing circuit are configured in a half-bridge topology. The balancing circuit is configured to balance a neutral midpoint of the DC power bus. The balanced split phase AC power or three phase AC power is accomplished by actively controlling the neutral midpoint of the DC power bus via the balancing circuit.

Abstract: A welding-type power supply that receives alternating current (AC) input power and converts the AC input power to direct current (DC) power to provide power for welding tools. The welding-type power supply is configured to detect whether single phase AC power or three-phase AC power is connected to the input of welding-type power supply. Single phase input power may be detected by sampling ripple voltage of the DC power, either synchronously with the AC input power or synchronously with a signal generated by an output of the welding-type power supply.

Abstract: Systems and methods to reduce magnetic flux in a switched mode power supply are disclosed. An example welding-type power supply includes a switched mode power supply, including a transformer configured to transform an input voltage to a welding-type voltage; switches configured to control a voltage applied to the primary winding of the transformer; a current detector configured to measure a current through the primary winding; a flux accumulator configured to determine a net flux in the transformer based on a number of volt-seconds applied to the primary winding of the transformer; and a controller configured to: control duty cycles of the switches based on the net flux; and set a value of the net flux in response to the current through the primary winding satisfying a current threshold.

Abstract: A method and apparatus provides welding-type power and preferably includes a removable battery or other energy storage device, a converter connected to the battery, and a controller. The controller may have a CV and/or a CSC and/or an AC weld control module, and/or an ac auxiliary control module. The converter is a boost converter, a buck converter, a cuk converter, a forward converter, an inverter, a bridge converter, and/or a resonant converter. The controller may include a battery charging control module, and may have one or more charging schedules, and/or data for stored charge, thermal information, expected life of the battery, maximum amp-hour charge for the battery, maximum charging current and/or feedback. The battery charging schedules may include at least 3 phases, such as a phase of increasing voltage and a phase of decreasing current, a substantially constant power phase. The controller can wirelessly provide data to a display or pda.

Abstract: A welding-type power supply includes a controller, a preregulator, a preregulator bus, and an output converter. The controller has a preregulator control output and an output converter control output. The preregulator receives a range of inputs voltages as a power input, and receives the preregulator control output as a control input, and provides a preregulator power output signal. The preregulator includes a plurality of stacked boost circuits. The preregulator bus receives the preregulator output signal. The output converter receives the preregulator bus as a power signal and receives the output converter control output as a control input. The output converter provides a welding type power output, and includes at least one stacked inverter circuit.

Abstract: A welding system is disclosed in which the rate of advancement of wire electrode is determined automatically. The device can include a control circuit that determines the rate of advancement of the wire electrode in response to a signal from the voltage selection device of the welding system. Depending upon the operator selected voltage which is selected via the voltage selection device, the control circuit will determine the appropriate rate of wire electrode advancement and control the advancement mechanism (e.g., electric motor) accordingly. Linking of the voltage level and wire-feed speed controls facilities easy of use for more novice operators and, furthermore, facilitates single-handed adjustment of two operational parameters during a welding process.

Abstract: A welding-type power supply includes a controller, a preregulator, a preregulator bus, and an output converter. The controller has a preregulator control output and an output converter control output. The preregulator receives a range of inputs voltages as a power input, and receives the preregulator control output as a control input, and provides a preregulator power output signal. The preregulator includes a plurality of stacked boost circuits. The preregulator bus receives the preregulator output signal. The output converter receives the preregulator bus as a power signal and receives the output converter control output as a control input. The output converter provides a welding type power output, and includes at least one stacked inverter circuit.

Abstract: A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter and a controller. The controller includes a pwm module that sets the pwm timing signals. The pwm module includes a phase shift module that has a leading edge adjusted output and a trailing edge adjusted output responsive to the output load. The phase shift module also includes a duty cycle offset module and/or a Dmax module that is responsive to the output load current. The pwm module includes a disabling module responsive to at least one of the output current and output voltage that disables one of the first and second converters.

Abstract: A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

Abstract: Systems and methods to estimate magnetic flux in a switched mode power supply are disclosed.