Abstract: A welding stud apparatus and method of manufacturing a welding stud are disclosed. The welding stud has a weld end constructed to be welded to a workpiece that has at least one recess formed therein. The recess decreases an effective arc area of the weld end to localize a current therethrough and increase the efficiency with which the welding stud can be welded to a workpiece.

Abstract: An appartus and method for a stud welder power source is disclosed. The power source has a control circuit connected to an inverter which converts an electrical signal from a power source into an electrical signal that can perform stud welding. The inverter conditions the power signal such that a current of at least 1000 amps can be generated nearly instantaneously. Additionally, having a power source that includes a control circuit with an inverter allows for a smaller and lighter appartus when compared to known stud welders.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: A method and apparatus for inductively heating a work piece. An induction heating system is used to produce a plurality of magnetic fields, each magnetic field extending through a portion of the work piece to inductively heat the work piece. At least one of the plurality of magnetic fields is oriented in a direction opposite to at least one other of the plurality of magnetic fields. The induction heating system may comprise an induction heating support structure adapted to receive the core. The induction heating system may also comprise an induction heating power source, a power source controller, an induction heating cable, and/or a fluid cooling unit.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the. switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the. switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a-coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: A method and apparatus for supply welding, plasma cutting, and/or induction heating power having a ground fault interrupt (GFI) protection circuit is disclosed. The primary winding of a monitoring transformer in the GFI protection circuit is connected between the high frequency floating output of the power supply and ground. One end of the secondary of the monitoring transformer is connected to a voltage source. The other end of the secondary is connected to an impedance. The other end of the impedance is connected back to the voltage source to form a voltage divider across the voltage source. Changes in the impedance between the floating output of the power supply and ground are sensed by the GFI protection circuit and converted into a voltage. This voltage is filtered, rectified, and calibrated into a dc sense signal. The sense signal is compared to a threshold signal. In the event the sense signal exceeds the threshold signal, an interrupt signal is sent to the power supply and the power supply shuts down.

Abstract: A method and apparatus for induction heating includes a power supply, and a controller, and an induction head. The induction head includes a flexible coiled, such as one formed with Litz wire. The head also includes a thermal insulator, for disposing between the head and the workpiece. The insulator reflects heat back to the workpiece, protecting the coil, but is transparent to inductive (E-M) energy. The power supply is a variable output frequency power supply, such as one having a resonant tank, to adapt to the inductance of the head.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: A method and system for system for welding a workpiece is disclosed. The workpiece is preheated while the weld is being performed. The preheating is performed fast enough that it can be done on-the fly- immediately in advance of the weld. The preheating is preferably accomplished with an induction heating system. The induction coil is mounted with the welding torch such that as the torch is moved along the weld path, the coil precedes it, preheating the weld path.

Abstract: A method and system for system for welding a workpiece is disclosed. The workpiece is preheated while the weld is being performed. The preheating is performed fast enough that it can be done on-the fly-immediately in advance of the weld. The preheating is preferably accomplished with an induction heating system. The induction coil is mounted with the welding torch such that as the torch is moved along the weld path, the coil precedes it, preheating the weld path.

Abstract: A method and apparatus for induction heating includes a power supply, and a controller, and an induction head. The induction head includes a flexible coiled, such as one formed with Litz wire. The head also includes a thermal insulator, for disposing between the head and the workpiece. The insulator reflects heat back to the workpiece, protecting the coil, but is transparent to inductive (E-M) energy. The power supply is a variable output frequency power supply, such as one having a resonant tank, to adapt to the inductance of the head.

Abstract: An induction heating power supply is disclosed. It includes a power circuit having at least one switch and a power output. The output circuit includes an induction head. The output circuit is coupled to the power output. A controller has at least one feedback input connected to the output circuit, and has a control output connected to the switch. The controller predicts the switch zero crossing and preferably soft switches the switch. Current feedback is obtained from a coil placed between the bus bars. Each bus bar is comprised of multiple plates to increase current capacity.

Abstract: An improved system for minimizing toll charges is disclosed wherein line quality is measured and a call is terminated if the line quality is not at an acceptable level to allow for the highest possible bit rates during data transfer or to guarantee a certain minimum degree of quality.