Abstract: A welding system is provided which utilizes a short arc welding method in which the waveforms have a positive polarity portion and negative portion to optimize heat input and provide heat and current control.

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 real time data collected from a performed or previously performed 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., real world welding procedure).

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: A multi-stage pulse ramp is employed during a welding process. In a first stage, a relatively slower increase in welding output is applied to stabilize a droplet. During a second stage, a relatively quicker increase is applied up to a peak pulse output to transfer the stabilized droplet.

Abstract: Embodiments of the present invention are directed to systems and methods of controlling wire feeding in a welding operation, where the wire feeding has a plurality of positive and negative pulses. Embodiments determine an average wire feed speed and compare the average to a desired wire feed speed and then change a parameter of the wire feed pulses to achieve a desired wire feed speed.

Abstract: The invention described herein generally pertains to a system and method for performing a welding operation that is controlled in part by a welding sequence. An input component is provided that receives an input from an operator during a performance of a welding operation in which the input allows control of the welding operation or feedback from the welding operation. In an embodiment, the input component is incorporated or affixed to equipment of the operator. An Radio Frequency Identification (RFID) tag is further utilized to control use of a welding sequence based on wireless data communicated between the RFID tag and an RFID component.

Abstract: An electric arc welding system and method includes providing a welding apparatus having at least a welding power supply, a wire feeder configured to supply a welding wire, a welding gun having an opening from which the welding wire extends, and a welding controller. The controller can initiate a weld ending process, which senses any contact between the welding wire and a workpiece. In response to any such contact, the controller executes a wire material transfer routine to transfer molten material of the welding wire from the welding wire to the workpiece. This routine can be repeated until the wire feeder stops advancing the welding wire towards the workpiece during the weld ending process.

Abstract: The invention described herein generally pertains to a system and method for collecting one or more welding parameters or a weld time during creation of one or more welds using a welding sequence. The one or more welding parameters and/or weld time for each welding sequence is utilized to determine an estimation of consumable depletion for a welding work cell and/or a repair/service to perform on equipment within the welding work cell. Furthermore, the weld time and/or welding parameters can be utilized to manage inventory for a plurality of welding work cells within a welding environment. Other embodiments provided track a cost for a performance of a weld with a welding sequence as well as identifying a workpiece to communicate information related to the one or more welds used for assembly.

Abstract: An arc welding system includes a welding torch, an electrode, and a power supply having a switching-type power converter connected to the torch. A parallel state-based controller is connected to the power converter and provides a waveform control signal thereto for controlling its operations. The controller generates a motion control signal for controlling movements of the electrode and/or the torch. A sensor senses welding voltage or welding current. A memory stores a welding state table comprising sequential control states, and stores a motion control system state table comprising further sequential control states. The welding waveform is defined in the welding state table. The controller controls the operations of the power converter through the waveform control signal according to the welding state table, simultaneously adjusting the motion control signal according to the motion control system state table. The controller transitions between control states according to the signal received from the sensor.

Abstract: Embodiments of the present invention are directed to systems and methods of controlling wire feeding in a welding operation, where the wire feeding has a plurality of positive and negative pulses. Embodiments determine an average wire feed speed and compare the average to a desired wire feed speed and then change a parameter of the wire feed pulses to achieve a desired wire feed speed.

Abstract: Embodiments of the present invention comprise a system and method to weld or join coated materials using an arc welding system alone, or in combination with a hot wire system, where the arc welding system uses a welding current having an AC current portion to build a droplet for transfer to the workpiece. In further embodiments, the workpiece is coated with a material, such as zinc, and the arc welding system uses an AC welding waveform which is capable of welding coated workpieces with little or no porosity or spatter and can achieve enhanced performance. Additional embodiments use an enhanced electrode to provide optimum porosity performance. Such embodiments allow for the welding of coated material with little or no porosity and spatter, and at a high welding rate.

Abstract: Embodiments of the present invention comprise a system and method to weld or join coated materials using an arc welding system alone, or in combination with a hot wire system, where the arc welding system uses a welding current having an AC current portion to build a droplet for transfer to the workpiece. In further embodiments, the workpiece is coated with a material, such as zinc, and the arc welding system uses an AC welding waveform which is capable of welding coated workpieces with little or no porosity or spatter and can achieve enhanced performance. Additional embodiments use an enhanced electrode to provide optimum porosity performance. Such embodiments allow for the welding of coated material with little or no porosity and spatter, and at a high welding rate.

Abstract: An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece. Molten metal droplets are quickly created during negative polarity portions of the weld cycle. Welding controls include integrating a parameter during the negative polarity portions to determine when a desired amount of energy has been generated at the welding wire. This energy is associated with a desired droplet size for consistent droplet transfers to the workpiece.

Abstract: A welder power supply and welding method are provided which utilizes a short arc welding method in which the waveforms have a positive polarity portion and negative portion to optimize heat input and provide heat and current control.

Abstract: A welder power supply and welding method are provided which welds in a DCEN state, but when a short circuit is detected the current waveform switches to an EP state and the short circuit is cleared while the electrode has a positive polarity.

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: An electric arc welding system and method includes providing a welding apparatus having at least a welding power supply, a wire feeder configured to supply a welding wire, a welding gun having an opening from which the welding wire extends, and a welding controller. The controller can initiate a weld ending process, which senses any contact between the welding wire and a workpiece. In response to any such contact, the controller executes a wire material transfer routine to transfer molten material of the welding wire from the welding wire to the workpiece. This routine can be repeated until the wire feeder stops advancing the welding wire towards the workpiece during the weld ending process.

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 of electric arc welding that includes a welding apparatus having a plurality of welding machines, e.g., tandem welding, and a synchronizing controller. The synchronizing controller controls the phase relationship of the welding waveforms associated with the welding machines. Portions of the welding waveforms can be modified to include a short-clearing routine that minimizes spatter. The synchronizing controller modifies portions of the welding waveforms such that the short-clearing intervals begin at different times to avoid interference between the signals associated with short-clearing.

Abstract: Embodiments of the present invention comprise a system and method to weld or join coated materials using an arc welding system alone, or in combination with a hot wire system, where the arc welding system uses a welding current having an AC current portion to build a droplet for transfer to the workpiece. In further embodiments, the workpiece is coated with a material, such as zinc, and the arc welding system uses an AC welding waveform which is capable of welding coated workpieces with little or no porosity or spatter and can achieve enhanced performance. Additional embodiments use an enhanced electrode to provide optimum porosity performance. Such embodiments allow for the welding of coated material with little or no porosity and spatter, and at a high welding rate.