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: 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-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: Embodiments of a welding power supply including a main power supply and a background power supply are provided. The main power supply includes a first transformer that supplies a first power output to welding electrodes for use in a welding operation. The background power supply includes a secondary transformer that charges an energy storage device to a regulated voltage level and is adapted to discharge the energy storage device by a controlled amount to supply a second regulated power output to the welding electrodes for use in the welding operation when a transient voltage event occurs.

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 power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A portable battery powered welder is disclosed that is configured to operate without an external power source. The portable battery powered welder may include a battery coupled to a welding circuit and a wire feeder. Further, the portable battery powered welder may include a suitcase to integrally support and completely enclose the welding circuit, the battery, and the wire feeder. The suitcase may include a lateral access door having a hinge and a latch. Additionally, the wire feeder and a wire spool may be disposed in a region accessible by the lateral access door. The suitcase may also include an access panel disposed over a region containing the battery. The access panel may be mounted to the case via a snap mount and/or secured via fasteners. Finally, the suitcase may include a top handle and may be made of a lightweight, impact resistant, and flame retardant material.

Abstract: A method and apparatus for air carbon arc cutting (CAC-A) using a welding-type power supply includes selecting a CAC-A mode and providing current in a CAC-A mode at a selected current setpoint. Start and restrike algorithms can be used that are specifically for CAC-A.

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: Methods, controllers, and power sources for controlling weld states of a MIG welding machine having a 115 volt inverter are provided. The regulation of a power source may include determining a command current signal based on a maximum allowable voltage error determined from the output condition at the weld. The signal may be provided to a controller that regulates the output of the 115 volt inverter. A MIG welding power source may include the 115 volt inverter and a processor that determines a maximum allowable voltage offset from a voltage feedback signal and a voltage level. The processor may provide a signal based on a determined instantaneous command current to regulate the 115 volt inverter.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A technique for dynamically adjusting an output voltage for a welding or cutting operation is provided. The technique allows for varying output voltage at the welding or cutting torch by manipulating the duty cycles of two forward converter circuits. The present disclosure provides methods and systems for increasing synchronized duty cycles in a pair of forward converter circuits in response to increasing output voltage demand then changing a phase shift between the duty cycles in response to further increases in output voltage demand. The present disclosure provides a controller designed to receive input signals and generate output pulse width modulation signals that control the duty cycle width and phase shift of the outputs of the forward converter circuits in response to these signals. Methods of accommodating for the time needed for the transformer core to reset via leading edge or lagging edge compensation are provided.

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 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 controller has a converter control output connected to the control input, and a flux balancing module. The converter control output is responsive to the flux balancing module such that the flux in the transformer remains balanced.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A technique for dynamically adjusting an output voltage for a welding or cutting operation is provided. The technique allows for varying output voltage at the welding or cutting torch by manipulating the duty cycles of two forward converter circuits. The present disclosure provides methods and systems for increasing synchronized duty cycles in a pair of forward converter circuits in response to increasing output voltage demand then changing a phase shift between the duty cycles in response to further increases in output voltage demand. The present disclosure provides a controller designed to receive input signals and generate output pulse width modulation signals that control the duty cycle width and phase shift of the outputs of the forward converter circuits in response to these signals. Methods of accommodating for the time needed for the transformer core to reset via leading edge or lagging edge compensation are provided.

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.