Abstract: Welding circuits including superposition elements that charge and discharge to assist with re-establishing a welding arc between an electrode and a workpiece after the arc is extinguished when a welding output current polarity changes are described.

Abstract: Systems and methods providing low current regulation for AC arc welding processes to regulate arc welding performance. In arc welding power source embodiments, configurations of bridge and arc regulation circuits allow for the directional switching of the welding output current through the welding output circuit path and induce a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The arc regulation circuit provides a high inductance level for storing energy, in both polarities, which induces the voltage level for re-igniting the arc during the zero crossing of the output current and provides low end stabilization of arc current.

Abstract: Welding circuits including superposition elements that charge and discharge to assist with re-establishing a welding arc between an electrode and a workpiece after the arc is extinguished when a welding output current polarity changes are described.

Abstract: A modified phase shift scheme that provides the minimum on-time and regulation benefits of the conventional phase shift method with the reduced circulating current benefits of the traditional PWM control. A welding machine comprises an inverter operatively connected to a controller, wherein the controller controls a welding process of the welding machine using modified phase shifted switching of the inverter.

Abstract: Systems and methods providing an energy limited arc re-ignition voltage for AC arc welding processes to re-ignite an arc during polarity transitions. In arc welding power source embodiments, configurations of bridge and superposition circuits allow for the directional switching of the welding output current through the welding output circuit path and provide a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The superposition circuit provides a capacitor for storing energy from a dedicated charging source which produces the voltage level for re-igniting the arc during the zero crossing of the output current in both polarities.

Abstract: Systems and methods for providing controlled AC arc welding processes. In arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from a consumable electrode to a workpiece and further aids in the maintaining or the re-establishing of an arc between the consumable electrode and the workpiece when a molten metal ball is transferred.

Abstract: A method of controlling a power source includes providing a power supply module. The power supply module includes a first circuit that has at least one first switch. The first circuit is configured to provide a welding current to an electrode of a welding system. The power supply module also has a second circuit that includes a load that is operatively connected to at least one second switch. The second circuit is configured to provide the welding current to the electrode through the load. The method also includes controlling the at least one first switch such that the welding current flows through the at least one first switch and to the electrode during a ramp up portion of a welding waveform and such that no current flows through the at least one first switch during a ramp down portion of the welding waveform. The method further includes controlling the at least one second switch such that the welding current flows through the load and to the electrode during the ramp down portion of the welding waveform.

Abstract: Systems and methods providing low current regulation for AC arc welding processes to regulate arc welding performance. In arc welding power source embodiments, configurations of bridge and arc regulation circuits allow for the directional switching of the welding output current through the welding output circuit path and induce a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The arc regulation circuit provides a high inductance level for storing energy, in both polarities, which induces the voltage level for re-igniting the arc during the zero crossing of the output current and provides low end stabilization of arc current.

Abstract: Systems and methods providing low current regulation for AC arc welding processes to regulate arc welding performance. In arc welding power source embodiments, configurations of bridge and arc regulation circuits allow for the directional switching of the welding output current through the welding output circuit path and induce a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The arc regulation circuit provides a high inductance level for storing energy, in both polarities, which induces the voltage level for re-igniting the arc during the zero crossing of the output current and provides low end stabilization of arc current.

Abstract: Systems and methods providing an energy limited arc re-ignition voltage for AC arc welding processes to re-ignite an arc during polarity transitions. In arc welding power source embodiments, configurations of bridge and superposition circuits allow for the directional switching of the welding output current through the welding output circuit path and provide a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The superposition circuit provides a capacitor for storing energy from a dedicated charging source which produces the voltage level for re-igniting the arc during the zero crossing of the output current in both polarities.

Abstract: Systems and methods for providing controlled AC arc welding processes. In arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from a consumable electrode to a workpiece and further aids in the maintaining or the re-establishing of an arc between the consumable electrode and the workpiece when a molten metal ball is transferred.

Abstract: Systems and methods providing low current regulation for AC arc welding processes to regulate arc welding performance. In arc welding power source embodiments, configurations of bridge and arc regulation circuits allow for the directional switching of the welding output current through the welding output circuit path and induce a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The arc regulation circuit provides a high inductance level for storing energy, in both polarities, which induces the voltage level for re-igniting the arc during the zero crossing of the output current and provides low end stabilization of arc current.

Abstract: A modified phase shift scheme that provides the minimum on-time and regulation benefits of the conventional phase shift method with the reduced circulating current benefits of the traditional PWM control. A welding machine comprises an inverter operatively connected to a controller, wherein the controller controls a welding process of the welding machine using modified phase shifted switching of the inverter.

Abstract: A plasma device including a power source for creating an AC output signal with a matrix transformer between said power source and a series circuit comprising a first lead and a second lead. The matrix transformer including at least two modules with a first primary portion formed of first and second tubes connected at one end and a second primary portion formed of third and fourth tubes connected at one end, with said third and fourth tubes mounted in, and electrically isolated from, said first and second tubes, respectively, where said concentric tubes define generally parallel elongated passages through the module. A secondary winding is wrapped through the elongated passages of each module.

Abstract: A plasma device including a power source for creating an AC output signal with a matrix transformer between said power source and a series circuit comprising a first lead and a second lead. The matrix transformer including at least two modules with a first primary portion formed of first and second tubes connected at one end and a second primary portion formed of third and fourth tubes connected at one end, with said third and fourth tubes mounted in, and electrically isolated from, said first and second tubes, respectively, where said concentric tubes define generally parallel elongated passages through the module. A secondary winding is wrapped through the elongated passages of each module.

Abstract: A plasma device including a power source for creating an AC output signal with a matrix transformer between said power source and a series circuit comprising a first lead and a second lead. The matrix transformer including at least two modules with a first primary portion formed of first and second tubes connected at one end and a second primary portion formed of third and fourth tubes connected at one end, with said third and fourth tubes mounted in, and electrically isolated from, said first and second tubes, respectively, where said concentric tubes define generally parallel elongated passages through the module. A secondary winding is wrapped through the elongated passages of each module.

Abstract: An inverter based power source for electric arc welding where the power source includes a high switching speed inverter for driving the primary side of an output transformer that has a primary circuit with current greater than 250 amperes and a secondary circuit with a current having an operating range with a maximum current greater than 700 amperes and an output rectifier to rectify the secondary current into a DC current suitable for welding.

Abstract: An electric arc welder comprising a high switching frequency inverter for driving the primary of an output transformer where the output transformer has a plurality of modules forming the secondary windings of the transformer and each of the modules comprises a first coaxial set of concentric, telescoped tubes separated by a tubular insulator, a second coaxial set of concentric, telescoped conductive tubes separated by a tubular insulator wherein the sets each have an elongated central passage for accommodating the primary and a conductor connecting the tubes into a series circuit. These modules form a transformer for such welder.

Abstract: In a power source for an electric arc welder including an inverter having two primary circuits connected in a series circuit across the DC bus of an input rectifier where each primary circuit comprises a capacitor parallel with a primary winding section and a switch to apply the voltage of the capacitor across the primary winding section, so that the primary circuits alternately create a voltage pulse in the primary winding sections to induce voltage pulses in a secondary circuit having a secondary winding coupled to said primary windings and connected by an output circuit to an output welding circuit. There is provided one improvement. The improvement is a soft ferrite saturable reactor in at least one of the series circuit or the output circuit to delay the voltage pulse in the primary winding sections.