Abstract: An example contact tip for a welding torch includes: a first body section having a first diameter and exterior threads, the first body section having channels extending longitudinally along an exterior surface of the first body section to permit gas flow from a first end of the contact tip to a second end of the contact tip through the channels; a first bore portion having a first inner diameter; and a second bore portion having a second inner diameter configured to contact an electrode wire traveling through the second bore portion, the first inner diameter being larger than the second inner diameter.

Abstract: A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.

Abstract: An example contact tip for a welding torch includes: a first body section having a first diameter and exterior threads, the first body section having channels extending longitudinally along an exterior surface of the first body section to permit gas flow from a first end of the contact tip to a second end of the contact tip through the channels; a first bore portion having a first inner diameter; and a second bore portion having a second inner diameter configured to contact an electrode wire traveling through the second bore portion, the first inner diameter being larger than the second inner diameter.

Abstract: A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.

Abstract: A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.

Abstract: A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command to drive the output current. Feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by adjustment of the current command. The short being about to clear is detected in real time. When the process is ending a very low current level is provided to avoid forming a ball. If a short is created, after the low current level, a burst of energy is provided to clear of burn off the short. After the short is cleared, very low current is again provided to avoid forming a large ball, until the wire stops and the process ends.

Abstract: A method and apparatus for multi process welding includes providing a controlled short circuit output and a pulse output in response to a user selection across a workpiece output stud and a torch output stud.

Abstract: A method and apparatus for providing welding power with an arc-width control is disclosed. The power supply includes a power circuit that provides a welding output characterized by a plurality of welding output parameters, and the power circuit receives at least one control input. A controller provides control signals to the power circuit. The controller receives user inputs for arc width and wire feed speed. The controller has an arc width control module that provides control signals that adjust one or more welding output parameters. The adjustment has a gain responsive to the wire feed speed input, such that there are at least three gains over a range of possible wire feed speeds, in one embodiment. The arc width control module provides control signals that adjust at least five welding output parameters in response to the wire feed speed input and the arc-width control input, in another embodiment.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command to drive the output current. Feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by adjustment of the current command. The short being about to clear is detected in real time. When the process is ending a very low current level is provided to avoid forming a ball. If a short is created, after the low current level, a burst of energy is provided to clear of burn off the short. After the short is cleared, very low current is again provided to avoid forming a large ball, until the wire stops and the process ends.

Abstract: A method and apparatus for providing welding-type power includes a source of welding-type power and a controller. The controller is a state-based controller, and/or a deterministic control module, connected to the controller output. The state-based control module includes, in an embodiment, software instructions and a digital processor, and/or a state transition table stored in a spreadsheet data base. The controller is responsive to a feedback circuit. One or more welding peripherals, such as a wire feeder or robot, are connected to the controller. The current state may be represented by data in a first line of a spreadsheet and a state-ending event by a second, perpendicular, line of a spreadsheet. The subsequent state is determined by the intersection of the first and second lines in another embodiment.

Abstract: A method and apparatus for welding is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.

Abstract: A method and apparatus for providing welding power with an arc-width control is disclosed. The power supply includes a power circuit that provides a welding output characterized by a plurality of welding output parameters, and the power circuit receives at least one control input. A controller provides control signals to the power circuit. The controller receives user inputs for arc width and wire feed speed. The controller has an arc width control module that provides control signals that adjust one or more welding output parameters. The adjustment has a gain responsive to the wire feed speed input, such that there are at least three gains over a range of possible wire feed speeds, in one embodiment. The arc width control module provides control signals that adjust at least five welding output parameters in response to the wire feed speed input and the arc-width control input, in another embodiment.

Abstract: The present invention includes a welding system that has at least two metal inert gas (MIG) welders configured to perform a cooperative pulsed MIG welding process. The welding system also includes at least one communications link connecting the at least two MIG welders to deliver at least one of subordination commands and superiority commands to either of the at least two MIG welders to synchronize the cooperative pulsed MIG welding process.

Abstract: A short circuit arc welding system is disposed. The control scheme uses a current command signal to drive the output current. The command signal is comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command. Arc voltage feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by an instantaneous, or short-by-short, adjustment of the current command. A function of the time derivative of arc power, less the time derivative of arc current, is used to detect, in real time, when the short is about to clear. A stop algorithm is employed that monitors the arc on a short-by-short basis. When the process is ending a very low current level is provided to avoid forming a ball.

Abstract: A method and apparatus for providing welding-type power includes a source of welding-type power and a controller. The controller is a state-based controller, and/or a deterministic control module, connected to the controller output. The state-based control module includes, in an embodiment, software instructions and a digital processor, and/or a state transition table stored in a spreadsheet data base. The controller is responsive to a feedback circuit. One or more welding peripherals, such as a wire feeder or robot, are connected to the controller. The current state may be represented by data in a first line of a spreadsheet and a state-ending event by a second, perpendicular, line of a spreadsheet. The subsequent state is determined by the intersection of the first and second lines in another embodiment.

Abstract: A method and apparatus for welding include initiating a pulse welding process includes initiating a welding arc by providing CC type welding power, maintaining the arc by providing CV type power. Then, pulse type welding power is provided. The method and system can be used to start short circuit, or other welding processes by providing short circuit power, or welding power of a given mode, instead of providing pulse power. Also, in one alternative, a method and system of initiating a pulse, short circuit, or given welding process includes initiating a welding arc by providing CC type welding power at least until a pseudo-equilibrium for the arc is established. Then, providing welding power in a pulse, short circuit, or the given mode.

Abstract: A method and apparatus for multi process welding includes providing a controlled short circuit output and a pulse output in response to a user selection across a workpiece output stud and a torch output stud.

Abstract: A method and apparatus for providing welding-type power includes a source of welding-type power and a controller. The controller is a state-based controller, and/or a deterministic control module, connected to the controller output. The state-based control module includes, in an embodiment, software instructions and a digital processor, and/or a state transition table stored in a spreadsheet data base. The controller is responsive to a feedback circuit. One or more welding peripherals, such as a wire feeder or robot, are connected to the controller. The current state may be represented by data in a first line of a spreadsheet and a state-ending event by a second, perpendicular, line of a spreadsheet. The subsequent state is determined by the intersection of the first and second lines in another embodiment.

Abstract: A system and method for stabilizing a welding arc is disclosed. The method of initiating the arc includes the steps of defining a wire feed speed based on a user selected wire feed speed and then abruptly reducing the wire feed speed before the wire feed speed reaches a relatively stabilized speed for welding, thereby allowing a welding arc to initiate and propagate to a generally steady state.