Abstract: A method and apparatus for short circuit welding includes providing welding power suitable for short circuit welding, sensing the stick out length, and adjusting the welding speed, such as wire feed speed or travel speed, adjusting a welding parameter, or adjusting the gas mixture in response thereto. Stick out is preferably determined by measuring a welding parameter, and performing an FFT on the parameter, and then calculating stick out, in one embodiment. Stick out can be either CTTWD or CPTPD. The system can determine when a short is about to clear by calculating a value Vc defined by Vc=d/dt(k1*dp/dt), and comparing Vc to a Vthreshold, which varies in response to welding cycle history.

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 providing welding-type power is disclosed and includes a short clearing prediction module that uses the second derivative with respect to time of the output voltage, or an error between a measured output voltage and an output voltage predicted using the first derivative with respect to time of the output voltage.

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 welding includes one or more of a welding type power source, a feedback circuit, a wire feeder and a controller. The controller preferably has an eta control circuit responsive to the feedback.

Abstract: A method and apparatus for MIG-MIG welding includes at least first and second sources (104,114) of wire, and first and second sources of power (102,112). The first source of wire provides a first wire (106) to a main arc between the first wire (106) and a workpiece (110). The first source of power (102) provides MIG power to a first current path including the first wire (106) and the workpiece (110). The second source of wire provides a second wire to a filler arc between the first wire (106) and the second wire (116). The second source of power (112) provides MIG power to a second current path including the first wire (106) and the second wire (116).

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 feeding wire from a source of wire to a weld includes one or more motors disposed adjacent the wire to drive the wire to the weld. A buffer is disposed between the source and an arc end of the torch. Another motor may be disposed near the wire source. A wire tension controller may be provided. The one or more motors advance and retract the wire, and wire is stored, or the path length altered, when the wire is retracted.

Abstract: A method and apparatus for feeding wire in a welding system include one or more motors disposed adjacent the wire to drive it. A wire feed motor is also disposed along the wire path, and is closer to the source of wire than the torch, and closer to the source than the one or more motors. The motors may be a pair motors disposed on opposite sides of the wire and move the wire to and away from an arc end of a torch. They preferably reversing the direction of the wire within one process cycle. The or more motors may be a stepper motor, a servo motor, a zero backlash motor, a gearless motor, a planetary drive motor, or a linear actuator (such as a piston), in various embodiments.

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 welding includes one or more of a welding type power source, a feedback circuit, a wire feeder and a controller. The controller preferably has an eta control circuit responsive to the feedback. It also has a control loop having a response time responsive to the eta output. The controller detects whether or not the process is a fast-tack process, and controls the supply of power according to a first control scheme is the process is a fast-tack process, and according to a second control scheme if the process is not a fast-tack process. The controller sets the run-in wire feed speed as a percentage of weld wire feed speed, preferably obtaining the percentage from the weld wire feed speed potentiometer at start up. The controller enters a calibration mode at start up if a calibration pendant is attached and on. In the calibration mode calibration receiving values from the front panel potentiometers.

Abstract: A method and apparatus for controlling a welding-type power supply includes providing a current wave form having an arc current portion and a short circuit current portion. An arc state is entered by retracting a welding wire, and a short circuit state is entered by advancing the wire. The current enters the arc current portion prior to the creation of the arc and the current enters the short circuit current portion prior to the creation of the short, by coordinating the wave form with the wire retraction. This may be preformed on a wire having a diameter of 2.4 mm or more to a weld and applying a welding current of less than 100 amps, or of less than 35 amps. One current waveform during the arc state includes at least three segments, and the last segment is entered into prior to the short circuit state being entered, and is the same current magnitude as the current magnitude at the start of the short circuit state.

Abstract: A method and apparatus for feeding wire in a welding system include one or more motors disposed adjacent the wire to drive it. A wire feed motor is also disposed along the wire path, and is closer to the source of wire than the torch, and closer to the source than the one or more motors. The motors may be a pair motors disposed on opposite sides of the wire and move the wire to and away from an arc end of a torch. They preferably reversing the direction of the wire within one process cycle. The or more motors may be a stepper motor, a servo motor, a zero backlash motor, a gearless motor, a planetary drive motor, or a linear actuator (such as a piston), in various embodiments.

Abstract: A method and apparatus for controlling a welding-type power supply includes providing a current wave form having an arc current portion and a short circuit current portion. An arc state is entered by retracting a welding wire, and a short circuit state is entered by advancing the wire. The current enters the arc current portion prior to the creation of the arc and the current enters the short circuit current portion prior to the creation of the short, by coordinating the wave form with the wire retraction. This may be preformed on a wire having a diameter of 2.4 mm or more to a weld and applying a welding current of less than 100 amps, or of less than 35 amps. One current waveform during the arc state includes at least three segments, and the last segment is entered into prior to the short circuit state being entered, and is the same current magnitude as the current magnitude at the start of the short circuit state.

Abstract: A system and method for controlling a wire feeder is disclosed. The speed by which a wire feeder delivers consumable weld wire to a weld is dynamically controlled based on feedback from a contact-less sensor. The contact-less sensor provides the feedback directly from the consumable weld wire as it is being delivered to a weld. The present invention is particularly applicable with MIG and CSC welding systems.

Abstract: A contact tip for a welding torch is provided. In one embodiment, the contact tip includes a body formed of an electrically conductive material and a non-linear passage that extends through the body. The non-linear passage of this embodiment is configured to receive a wire electrode and to facilitate electrical communication between the body and the wire electrode. Various contact tip assemblies and manufacturing techniques for forming contact tips are also provided.

Abstract: A welding gun is disclosed that includes an electrode configured to effectuate a welding-type process and a non-conductive nozzle configured to at least partially surround the electrode. The welding gun also includes a conductive casing at least partially surrounding the nozzle and electrically isolated from the electrode and a conductive path extending from the conductive casing through the welding gun.

Abstract: A method and apparatus for welding includes one or more of a welding type power source, a feedback circuit, a wire feeder and a controller. The controller preferably has an eta control circuit responsive to the feedback. It also has a control loop having a response time responsive to the eta output. The controller detects whether or not the process is a fast-tack process, and controls the supply of power according to a first control scheme is the process is a fast-tack process, and according to a second control scheme if the process is not a fast-tack process. The controller sets the run-in wire feed speed as a percentage of weld wire feed speed, preferably obtaining the percentage from the weld wire feed speed potentiometer at start up. The controller enters a calibration mode at start up if a calibration pendant is attached and on. In the calibration mode calibration receiving values from the front panel potentiometers.

Abstract: A system having a welding wire hub with a wire-specific interface. The wire-specific interface may be configured to enable mounting with a first wire spool and configured to prevent mounting with a second wire spool. In some embodiments, the first and second wire spools have different welding wire types.

Abstract: A method and apparatus for feeding wire in a welding system include one or more motors disposed adjacent the wire to drive it. A wire feed motor is also disposed along the wire path, and is closer to the source of wire than the torch, and closer to the source than the one or more motors. The motors may be a pair motors disposed on opposite sides of the wire and move the wire to and away from an arc end of a torch. They preferably reversing the direction of the wire within one process cycle. The or more motors may be a stepper motor, a servo motor, a zero backlash motor, a gearless motor, a planetary drive motor, or a linear actuator (such as a piston), in various embodiments.