Abstract: A method and apparatus provides welding-type power and preferably includes a removable battery or other energy storage device, a converter connected to the battery, and a controller. The controller may have a CV and/or a CSC and/or an AC weld control module, and/or an ac auxiliary control module. The converter is a boost converter, a buck converter, a cuk converter, a forward converter, an inverter, a bridge converter, and/or a resonant converter. The controller may include a battery charging control module, and may have one or more charging schedules, and/or data for stored charge, thermal information, expected life of the battery, maximum amp-hour charge for the battery, maximum charging current and/or feedback. The battery charging schedules may include at least 3 phases, such as a phase of increasing voltage and a phase of decreasing current, a substantially constant power phase. The controller can wirelessly provide data to a display or pda.

Abstract: A method and apparatus provides welding-type power and preferably includes a removable battery or other energy storage device, a converter connected to the battery, and a controller. The controller may have a CV and/or a CSC and/or an AC weld control module, and/or an ac auxiliary control module. The converter is a boost converter, a buck converter, a cuk converter, a forward converter, an inverter, a bridge converter, and/or a resonant converter. The controller may include a battery charging control module, and may have one or more charging schedules, and/or data for stored charge, thermal information, expected life of the battery, maximum amp-hour charge for the battery, maximum charging current and/or feedback. The battery charging schedules may include at least 3 phases, such as a phase of increasing voltage and a phase of decreasing current, a substantially constant power phase. The controller can wirelessly provide data to a display or pda.

Abstract: A method and apparatus for welding with an engine driven inverter power supply includes generating an ac output with an engine and generator. The output is rectified and inverted to provide an ac inverter output. The engine is controlled using feedback indicative of a welding output operating parameter. The feedback may also be taken from the inverter or generator, and the generator may be controlled instead of or in addition to the engine. Engine parameters that may be controlled include engine speed, selecting between an idle speed and a run speed, a throttle position, a fuel pump, an injection timer, a fuel to air ratio, fuel consumption and ignition timing. Another aspect of the invention is having the feedback be responsive to one or more of the welding current, welding voltage, welding power, or functions thereof. The feedback may be responsive to the current, voltage, power, ripple and functions thereof.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: A power supply connector includes a cable receptacle, a front bulkhead insulator and a rear bulkhead insulator. The bulkhead insulators are mounted on the cable receptacle and the power supply chassis. At least one O ring is disposed between the front and rear bulkhead insulators, to seal out water. The front bulkhead insulator includes a stepped portion that mates with a stepped portion on the rear bulkhead insulator. The front bulkhead insulator provides an elongated path from the chassis to the cable receptacle. Also, an O ring is disposed between the cable receptacle and the front bulkhead insulator, to seal out water.

Abstract: A power supply connector includes a cable receptacle, a front bulkhead insulator and a rear bulkhead insulator. The bulkhead insulators are mounted on the cable receptacle and the power supply chassis. At least one O ring is disposed between the front and rear bulkhead insulators, to seal out water. The front bulkhead insulator includes a stepped portion that mates with a stepped portion on the rear bulkhead insulator. The front bulkhead insulator provides an elongated path from the chassis to the cable receptacle. Also, an O ring is disposed between the cable receptacle and the front bulkhead insulator, to seal out water.