Abstract: A welding power supply and method are provided with a single welding mode in its controller such that the power supply can change from full DCEN output to AC output to a full DCEP output without having to change welding modes.

Abstract: A system for providing visual cues to a welder via an augmented reality display for a sequence of operations. The system includes an imaging device that identifies the orientation of an assembly to be welded. Welding operations are associated with locations on the assembly where the welder is to perform the operation. Based on the current field of view and the orientation of the assembly, the system determines whether the location on the assembly is within the field of view of the welder and provides a visual cue to the welder based on the orientation and the field of view. The power source of the welding device may be varied based on the image data received during the welding process.

Abstract: The invention described herein generally pertains to a system and method for welder system that relates to creating a welding sequence for a welding environment in which the welding sequence is based upon non-real time data collected from a welding procedure. Welding procedure information is collected and utilized to create a welding sequence to perform two or more welds in which at least one parameter is based on the collected welding procedure information (e.g., non-real world welding procedure).

Abstract: Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

Abstract: An electric arc welder and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode and a workpiece. The welder includes a short-detecting capability for detecting a short condition upon occurrence of a short circuit between the advancing electrode and the workpiece. The welder may also include a switching module in the welding circuit path of the welder having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module, for example.

Abstract: Systems and methods for determining that a consumable welding package has been, or may have been, replenished in a high production welding environment and that a tracked weight value of the consumable welding package should be reset. An operator of a welding system can be notified that a consumable welding package may have been replenished and, therefore, that the weight value of the consumable welding package may need to be reset in the welding system. Alternatively, the weight value of the consumable welding package in the welding system may be automatically reset when the welding system has determined that the consumable welding package has been replenished.

Abstract: An arc welding system and methods. The system is capable of monitoring variables during a welding process, according to wave shape states, and weighting the variables accordingly, detecting defects of a weld, diagnosing possible causes of the defects, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: An arc welding system and method where burnback time (BBT) is correlated to wire feed speed (WFS). Means for feeding a wire electrode toward a workpiece and means for selecting a wire feed speed (WFS) are provided. Also, means for automatically adjusting a burnback time (BBT) of the wire electrode in response to the selected wire feed speed (WFS) is provided.

Abstract: Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

Abstract: An electric arc welder and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode and a workpiece. The welder includes a short-detecting capability for detecting a short condition upon occurrence of a short circuit between the advancing electrode and the workpiece. The welder may also include a switching module in the welding circuit path of the welder having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module, for example.

Abstract: A system and method for controlling heating current for hot-wire processes in any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle. The system also includes a feeder subsystem that includes a wire feeder configured to feed a filler wire to the molten puddle, a first power supply configured to supply a first current through a first length of the filler wire, and a second power supply configured to supply a second current through a second length of the filler wire. The first current and the second current provide a power sufficient to resistance-heat the filler wire to at or near a melting temperature of the filler wire, and in some embodiment, the first power supply provides more than 50% of the power.

Abstract: Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

Abstract: A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on one of a desired RMS voltage set point and a desired RMS voltage range. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform.

Abstract: A system and method for controlling a hybrid welding process. An integrated hybrid welding power source includes a first power supply for providing a first welding output and a second power supply for providing a second welding output. The first power supply and the second power supply are operatively connected to coordinate the first welding output with the second welding output in real time while operating concurrently.

Abstract: A semi-automatic welding work cell, including a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by way of elapsed time, a detection of welding operations, a detection of the amount of welding wire supplied for the welding operation, or a detection of the amount of energy supplied for the welding operation.

Abstract: A semi-automatic welding work cell, including a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by way of elapsed time, a detection of welding operations, a detection of the amount of welding wire supplied for the welding operation, or a detection of the amount of energy supplied for the welding operation.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A system and method of welding is provided where welding power supply has a first output electrically coupled to a welding electrode and a second output electrically coupled to a switching mechanism. The welding power supply provides a welding current through either of the first and second outputs to weld at least one work piece. The switching mechanism has at least a first and second switch position, where the first switch position is coupled to a first position on the at least one work piece and the second switch position is coupled to a second position on the at least one work piece, which is remote from the first position. During welding the switching mechanism switches between the first and second switch positions to change a current path for the welding current during through the at least one work piece.

Abstract: Systems and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance.

Abstract: A system and method of starting a welding operation is provided where an electrode is advanced towards a work piece in a pulsed fashion and having a voltage level which will provide a first current when contact between the electrode and the work piece is made. After contact the electrode is retracted so that a welding arc is established and after the welding arc is established the current and wire feed speed is increased to a welding level.