Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.

Abstract: A welding-type system with a programmed controller and alert devices for alerting a user as to the impending thermal shutdown of the welding-type system.

Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.

Abstract: Methods and apparatus to communicate via a welding arc are disclosed. An example welding-type power supply includes a power converter, a weld monitor, and an arc modulator. The power converter outputs welding power to sustain a welding-type arc at a welding-type torch. The weld monitor monitors one or more aspects of a weld performed using the welding-type arc and the welding-type torch, and selects an audio message based on the one or more aspects. The arc modulator configured to modify the welding-type arc to output the selected audio message as a plasma speaker.

Abstract: Systems and methods are provided for indicating schedules in welding-type torches. A welding-type system may comprise a welding-type power source, a welding-type torch, driven by the welding-type power source, and a welding-type connector configured for connecting the welding-type power source to the welding-type torch. The welding-type torch may comprise one or more indication components configured for providing, to a user of the welding-type system, indications relating to at least one of operations of the welding-type torch, status of welding-type operations, or welding-type parameters. The one or more indications comprise an indication of a present value of a particular welding-type parameter that pertains to configuration of the welding-type power source; and the one or more indication components are configured to provide the indication of present value of the particular welding-type parameter without requiring a change to structure of the welding-type connector.

Abstract: Systems and methods are provided for selecting welding schedules in welding-type torches. A welding-type torch configured for use during welding-type operations, with the welding-type torch comprising an input device configured for setting a welding-type parameter, such as welding schedules, associated with a welding-type device that is used in conjunction with the welding-type torch during the welding-type operations. The welding-type device may be a welding-type power source. The welding-type torch is connected to the welding-type device via a welding-type connector, with the setting of the welding-type parameter occurring via the welding-type connector and without requiring a change to structure of the welding-type connector.

Abstract: Systems and methods are provided for visually displaying thermal duty cycles. Remaining weld time may be determined in a welding-type apparatus based on one or more parameters that correspond to at least one of: a real-time measurement corresponding to ambient conditions, a real-time measurement corresponding to power consumption, and a thermal profile of the welding apparatus. The information relating to the indication of remaining weld time may be presented to an operator of the welding-type system. The welding-type power supply may be shut off when a shut off threshold is satisfied.

Abstract: Welding-type systems and user interfaces having a color display for displaying physical setup instructions are disclosed. Example interface devices include a process selection input device, a display device, a memory, and a processor. The memory stores weld connection setup graphics and physical welding connections. Each of the plurality of weld connection setup graphics is a graphic of a perspective view of a power supply. The processor, in response to identifying a selected welding process type via the welding process selection input device, displays one of the plurality of the weld connection setup graphics via the display device. The processor detects a physical welding connection made at the power supply, determines, based on the detected physical welding connection, that the detected physical welding connection is incorrect for the selected welding process type, and displays an alert on the display device to indicate an error in the detected physical welding connection.

Abstract: Methods and apparatus to control advancement of a welding electrode wire for arc ignition are disclosed. An example electrode wire feeder includes a wire feed motor to advance electrode wire to a welding torch, a temperature monitor to determine a temperature of the electrode wire using at least one of a temperature measurement or a thermal model, and a motor controller to control a run-in wire speed based on a temperature of the electrode wire.

Abstract: A welding-type system with a programmed controller and alert devices for alerting a user as to the impending thermal shutdown of the welding-type system.

Abstract: Methods and apparatus to control hot-start weld current for arc ignition are disclosed. An example welding-type power supply includes a power converter to output welding-type current, a temperature monitor to determine a temperature of an electrode using at least one of a temperature measurement or a thermal model, and a current controller to control a hot-start weld current output by the power converter based on the temperature of the electrode.

Abstract: Systems and methods for providing a constant current controller for use in constant current welding applications are described. In one embodiment, a current controller controls the output current of the welding torch without directly measuring the output current of the welding torch. The current controller controls or sets a current in a primary winding of a transformer in an inverter of a welding power supply to control the output current of the welding torch.

Abstract: Systems and methods for providing welding power supplies with interleaved inverter circuitry are described. In one embodiment, a welding power supply includes, for example, a first inverter circuit and a second inverter circuit that are arranged in parallel. A voltage source or a current source is coupled to a first same node of the first inverter circuit and the second inverter circuit. A filter inductor is coupled to a second same node of the first inverter circuit and the second inverter circuit. The output current of the filter inductor is halved in frequency by disabling one of the first inverter circuit and the second inverter circuit.

Abstract: In certain embodiments, a welding system includes an interface with a first input element configured to receive an input relating to a parameter of power delivered to a welding torch from a welding power supply, a second input element configured to receive an input relating to a rate of advancement of an electrode delivered to the welding torch from a welding wire feeder, a third input element configured to receive an input relating to whether the parameter of power and the rate of advancement of the electrode are automatically set, and a color display device configured to display the parameter of power and the rate of advancement of the electrode.

Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.

Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.

Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding electrode. The power source comprises a positive stud and a negative stud. The welding system also includes control circuitry configured to determine whether the welding electrode is properly connected to the positive and negative studs of the power source.

Abstract: A system and method for automatic detection of a connection of a spool gun to a welding system. In addition to automatically detecting connection of the spool gun, a system and method is provided for controlling the operation of the welding system based on the detection of the spool gun.

Abstract: A welding system includes an interface having a first input element configured to receive an input relating to a parameter of power delivered to a welding torch from a welding power supply and to alternatively receive an input relating to a thickness of a work piece, a second input element configured to receive an input relating to a rate of advancement of an electrode delivered to the welding torch from a welding wire feeder and to alternatively receive an input relating to a diameter of the electrode, and a third input element configured to receive an input relating to a welding process type. The welding system also includes control circuitry configured to automatically adjust the parameter of the power and the rate of advancement of the electrode based on the input relating to the welding process type selected with the third input element when the second input element receives the input relating to the diameter of the electrode.

Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.