Abstract: The present invention is directed to an apparatus and method for a welding-type wire feeder. The feeder includes at least one electronically commutated motor (ECM) configured to deliver a consumable for a welding-type process. The feeder includes a controller configured to electronically commutate the at least one ECM so as to precisely perform push and pull functions, speed and acceleration control, and wire reversal.

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: The present invention is directed to a remotely controlled welding machine that uses serializing and modulating circuits to transfer modulated data packets to a welding power source across a weld cable. A transmitter transmits the data packets of desired welding operational parameters to a receiver disposed in the power source across a weld cable also designed to carry welding power from the power source to the wire feeder. The transmitter and other electronics of the wire feeder are constructed to use only a small amount of power which, preferably, is supplied by a DC power supply external to the wire feeder. The DC power supply is designed to provide power to the electronics of the wire feeder when the wire feeder is in a standby mode of operation.

Abstract: A system and method of duplicating CV mode of operation with a CC power includes a wire feeder designed to automatically adjust the speed of which consumable wire is delivered to a weld so as to maintain a target voltage set by a user. The wire feeder is designed to be operational on a CC power source yet automatically adjust the WFS so that a user-selected target voltage is maintained at the weld. A controller within the wire feeder is programmed to read an input from the user to the wire feeder identifying a target voltage and control the speed by which a drive assembly delivers metal filler to the weld based on the target voltage. By automatically adjusting the WFS, the user is not required to manually adjust the WFS to maintain the target voltage at the weld.

Abstract: The present invention is directed to a power supply that maintains power supply to a plurality of electronic components of a welding system when an arc voltage falls below approximately 15 volts. The invention includes a power supply having a secondary supply circuit that improves the operable range of the power supply by maintaining power to components of a welding system when the arc voltage at a weld is greater than or equal to approximately 10 volts. As a result, the operable range of the power supply is no longer limited by the arc voltage. The invention includes a secondary power supply circuit having a power switch that when activated causes a buildup of energy in the transformer assembly whereupon deactivation of the power switch in the magnetic core is exhausted such that power supply is maintained. The power switch regulates the transformer assembly such that sufficient secondary power is provided if the input voltage to the transformer is as low as approximately 10 volts.

Abstract: A system and method of duplicating CV mode of operation with a CC power includes a wire feeder designed to automatically adjust the speed of which consumable wire is delivered to a weld so as to maintain a target voltage set by a user. The wire feeder is designed to be operational on a CC power source yet automatically adjust the WFS at a rate of adjustment based on initial WFS so that a user-selected target voltage is maintained at the weld. A controller within the wire feeder is programmed to read an input from the user to the wire feeder identifying a target voltage, determine the rate of adjustment, and control the speed by which a drive assembly delivers metal filler to the weld based on the target voltage. By automatically adjusting the WFS, the user is not required to manually adjust the WFS to maintain the target voltage at the weld.

Abstract: The present invention is directed to a power supply that maintains power supply to a plurality of electronic components of a welding system when an arc voltage falls below approximately 15 volts. The invention includes a power supply having a secondary supply circuit that improves the operable range of the power supply by maintaining power to components of a welding system when the arc voltage at a weld is greater than or equal to approximately 10 volts. As a result, the operable range of the power supply is no longer limited by the arc voltage. The invention includes a secondary power supply circuit having a power switch that when activated causes a buildup of energy in the transformer assembly whereupon deactivation of the power switch in the magnetic core is exhausted such that power supply is maintained. The power switch regulates the transformer assembly such that sufficient secondary power is provided if the input voltage to the transformer is as low as approximately 10 volts.

Abstract: A method and apparatus for welding include a source of power, a wire feeder and a controller. The controller sends control signals to the wire feeder and the source of power. The controller also has an adjustable arc control input, and the controller controls at least three welding parameters in response to the arc control input. The arc control input may be an arc width input, and the controller may simultaneously control at least three welding parameters to obtain a desired arc width. The at least three welding parameters may include at least three of peak welding current, background welding current, pulse width, and frequency and the arc control input may be a user-selectable input.