Abstract: A system for controlling a welding operation provides for open-loop control of voltage applied to a wire electrode during an initial arc initiation stage of operation. The voltage may be based upon an operator set voltage. Electrode wire feed speeds may be varied during the same period. The voltage may be changed, but still open-loop controlled after initial contact between the electrode and a workpiece. The control transitions from open-loop to closed loop following the arc initiation stage, which may be a fixed interval or varied based upon various factors. Closed-loop voltage control then ensues, in which voltage may be limited to values based upon the initial open-loop voltage. The voltage may be regulated by control of SCR firing angles, such as by reference to a zero-crossing of an input AC waveform.

Abstract: The present invention is directed to a portable welding-type power source including a removable energy storage device configured to provide a first voltage output and a boost circuit connected to the energy storage device and configured to boost the first voltage output to a second voltage output to supply power to the welding-type power source according to a selected welding-type process.

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 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 welder having an internal shielding gas regulator is disclosed. The welder has an internal gas cylinder and an internal regulator disposed in an enclosure. The welder may be equipped with an auxiliary shielding gas cylinder inlet so that a bulk shielding gas cylinder can be attached thereto and have a flow therefrom regulated by the internal shielding gas regulator. The welder constructed according to the invention is highly transportable, compact, and self-sufficient.

Abstract: The present invention is directed to a MIG welding machine having a 115 volt inverter. Incorporation of the 115 volt inverter into the MIG welding power source reduces the weight of the power source thereby increasing its portability. The power source may include a power factor correction circuit to provide a near-unity power factor such that output power of the inverter is more efficiently provided. Additionally, the 115 volt inverter is constructed such that for short periods of time, the inverter may output power at a level that exceeds its power rating.

Abstract: The present invention is directed to a MIG welding machine having a 115 volt inverter. Incorporation of the 115 volt inverter into the MIG welding power source reduces the weight of the power source thereby increasing its portability. The power source may include a power factor correction circuit to provide a near-unity power factor such that output power of the inverter is more efficiently provided. Additionally, the 115 volt inverter is constructed such that for short periods of time, the inverter may output power at a level that exceeds its power rating.

Abstract: A welder having an internal shielding gas regulator is disclosed. The welder has an internal gas cylinder and an internal regulator disposed in an enclosure. The welder may be equipped with an auxiliary shielding gas cylinder inlet so that a bulk shielding gas cylinder can be attached thereto and have a flow therefrom regulated by the internal shielding gas regulator. The welder constructed according to the invention is highly transportable, compact, and self-sufficient.

Abstract: The present invention is directed to a portable welding-type power source including a removable energy storage device configured to provide a first voltage output and a boost circuit connected to the energy storage device and configured to boost the first voltage output to a second voltage output to supply power to the welding-type power source according to a selected welding-type process.

Abstract: The present invention is directed to a MIG welding machine having a 115 volt inverter. Incorporation of the 115 volt inverter into the MIG welding power source reduces the weight of the power source thereby increasing its portability. The power source may include a power factor correction circuit to provide a near-unity power factor such that output power of the inverter is more efficiently provided. Additionally, the 115 volt inverter is constructed such that for short periods of time, the inverter may output power at a level that exceeds its power rating.

Abstract: A welder having an integrated gas cylinder is disclosed. The welder has a power source constructed to condition and output an electrical signal suitable to welding and a gas cylinder disposed in an enclosure.

Abstract: A method and apparatus for welding power includes an input rectifier, a pre-regulator, a convertor, an auxiliary voltage circuit and a controller. The pre-regulator is connected to receive a rectified voltage and provides a dc bus. The convertor converts the bus to a welding output. The auxiliary voltage circuit is connected across the welding output, in parallel with the converter. The controller shuts the converter down in the event an open circuit condition exists at the output, thus providing a safer open circuit voltage.