Abstract: A linear DC welder for enhanced welding capabilities comprises one or more active filtering circuits. The active filtering circuit(s) are capable of producing a variety of user-configurable and user-controllable custom waveforms for use in various welding applications. The custom waveforms may be created and combined via the use of overlay waveforms and, in at least some preferred embodiments of the present invention, include agitation waveforms. The overall operation of the welder, including the power supply and the active filtering circuit can be controlled via an integrated feedback cycle that provides for the monitoring and adjustment of multiple weld process parameters including volts, amps, power, resistance, and displacement. Additionally, a low current ignition (“LCI”) circuit may also be included to provide for additional welding options.

Abstract: Disclosed herein is a capacitive discharge welder that comprises a series of super capacitors (or ultra-capacitors) used as a power source. The capacitive discharge welder disclosed herein also comprises a dual function circuit that serves as an emergency stop circuit that is capable of redirecting or disconnecting the weld path in certain applications and situations and a drain circuit to drain a filter capacitor. The capacitive discharge welder disclosed herein is configured to use the super capacitor power supply in a direct discharge configuration as a CD welder. Additionally, the super capacitors are switched at frequency through a filter capacitor to produce a shaped DC welding waveform suitable for a wide variety of welding applications.