Abstract: Systems and methods for determining welding parameters using material thickness and wire diameter are disclosed. An example welding-type system includes a power source; an input device configured to receive a first user input specifying a thickness of a material to be welded; and control circuitry configured to: determine a plurality of welding parameters based on the first user input and based on a user-specified wire diameter; control the power source based on one or more of the welding parameters; and control a wire feeder based on one or more of the welding parameters.

Abstract: Systems and methods for determining welding parameters using material thickness and wire diameter are disclosed. An example welding-type system includes a power source; an input device configured to receive a first user input specifying a thickness of a material to be welded; and control circuitry configured to: determine a plurality of welding parameters based on the first user input and based on a user-specified wire diameter; control the power source based on one or more of the welding parameters; and control a wire feeder based on one or more of the welding parameters.

Abstract: A drive assembly is provided for driving welding wire through a welding wire feeder. The drive assembly comprises an insulating base and a conductive base secured to one another. Both bases have features that allow for mounting in the wire feeder and for mounting various drive components. The conductive base is energized during operation, and the isolative base insulates the conductive base from components of the wire feeder enclosure. Features of the assembly improve operation and facilitate assembly.

Abstract: A welding-type component is disclosed having a single user input that requires a user to input only a single parameter to identify a welding-type process. From the single input, operating parameters for the welding-type process automatically are set or otherwise determined. The invention streamlines the welding-type process prescription process by allowing a user to input only a single parameter than can be used to determine and coordinate other parameters for the welding-type process.

Abstract: Systems and methods for determining welding parameters using material thickness and wire diameter are disclosed. An example welding-type system includes a power source; an input device configured to receive a first user input specifying a thickness of a material to be welded; and control circuitry configured to: determine a plurality of welding parameters based on the first user input and based on a user-specified wire diameter; control the power source based on one or more of the welding parameters; and control a wire feeder based on one or more of the welding parameters.

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 power circuit, in certain embodiments, includes an inductor to limit current through a capacitor, wherein the capacitor is configured to smooth ripple for a constant voltage welding system. More specifically, the power circuit may include a rectifier configured to convert AC power to DC power. The rectifier may be coupled to a DC bus configured to transmit the DC power. A capacitive circuit having the capacitor may be coupled across the DC bus to smooth ripple in the DC power. The inductor, e.g., coupled between the DC bus and the capacitive circuit, limits the rate of current flow between the capacitive circuit and the DC bus during a welding operation, thereby reducing heating in the output capacitive circuit. A further inductor may be coupled to one side of the DC bus to stabilize the rate of current flow from the power circuit to a load.

Abstract: A drive assembly is provided for driving welding wire through a welding wire feeder. The drive assembly comprises an insulating base and a conductive base secured to one another. Both bases have features that allow for mounting in the wire feeder and for mounting various drive components. The conductive base is energized during operation, and the isolative base insulates the conductive base from components of the wire feeder enclosure. Features of the assembly improve operation and facilitate assembly.

Abstract: A welding-type component is disclosed having a single user input that requires a user to input only a single parameter to identify a welding-type process. From the single input, operating parameters for the welding-type process automatically are set or otherwise determined. The invention streamlines the welding-type process prescription process by allowing a user to input only a single parameter than can be used to determine and coordinate other parameters for the welding-type process.

Abstract: A welding-type component is disclosed having a single user input that requires a user to input only a single parameter to identify a welding-type process. From the single input, operating parameters for the welding-type process automatically are set or otherwise determined. The invention streamlines the welding-type process prescription process by allowing a user to input only a single parameter than can be used to determine and coordinate other parameters for the welding-type process.

Abstract: A power circuit, in certain embodiments, includes an inductor to limit current through a capacitor, wherein the capacitor is configured to smooth ripple for a constant voltage welding system. More specifically, the power circuit may include a rectifier configured to convert AC power to DC power. The rectifier may be coupled to a DC bus configured to transmit the DC power. A capacitive circuit having the capacitor may be coupled across the DC bus to smooth ripple in the DC power. The inductor, e.g., coupled between the DC bus and the capacitive circuit, limits the rate of current flow between the capacitive circuit and the DC bus during a welding operation, thereby reducing heating in the output capacitive circuit. A further inductor may be coupled to one side of the DC bus to stabilize the rate of current flow from the power circuit to a load.

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 system for arc welding includes a welding power supply and a wire feeder. The wire feeder includes a dc wire feed motor and a dc wire feed power supply in electrical communication with the wire feed motor. A PTC thermistor is disposed electrically between the power supply and the wire feed motor. Current flows from the power supply, through the PTC thermistor, and then to the motor. Under normal current conditions the PTC thermistor allows current to be provided to the wire feed motor from the power supply, but under excessive current conditions the PTC thermistor inhibits current from being provided to the wire feed motor from the power supply. A diode is connected in anti-parallel with the motor. A pulse width modulation switch control current delivered to the motor. A normally open relay is closed when welding is to be performed to provide current to the motor, and a normally closed relay, connected in parallel with and shunting the motor, is opened when welding is to be performed.

Abstract: A method and apparatus for wire feeding in an arc welding system includes a wire feed motor and a controller. The controller has an input circuit and an intermediate control signal. The input circuit includes a user selectable wire feed speed input, and the intermediate control signal is responsive to the user selectable wire feed speed input. The user selectable wire feed speed input includes a nonlinear potentiometer, that may be an arcuate, trimmed, potentiometer and provides either step or varying changes in the nonlinear first response, to produce at least two slopes or a varying slope. The intermediate control signal has a first response relative to the user selectable wire feed speed input. The wire feed speed has a second response relative to the intermediate control signal that is undesiredly nonlinear over a range. The wire feed speed has an overall response relative to the user selectable wire feed speed input.