Abstract: A method and apparatus for starting a wire fed weld operation includes monitoring at least one of a prior run-in time, a prior run in distance, a prior run in wire feed speed, and/or whether or not there is contact at the time of a prior start. Then the wire position is controlled for a present weld operation in response to the monitored data.

Abstract: An example method of controlling a short circuit welding process includes: setting a heat target for at least a portion of a short state; monitoring output parameters during the short state; calculating a measured heat from the measured output parameters; comparing the measured heat and the heat target; adjusting a pinch current in a subsequent short state in response to at least one comparing from at least one previous short state; and repeating these actions.

Abstract: A method and apparatus for short circuit welding is disclosed. They reduce the current prior to the short clearing by adjusting waveform parameters in response to past cycles. One or more parameter of the output is monitored and compared to one or more targets, and future waveform parameters are adjusted so that the monitored parameters are more likely to reach the one or more targets.

Abstract: Systems and methods to start arc welding are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: prior to a welding operation, control the power conversion circuitry to stop outputting the welding-type power to a wire electrode; and in response to identifying contact between the wire electrode and a workpiece: control the power conversion circuitry to output an arc starting current to the wire electrode; control a feed motor of a welding torch to retract the wire electrode; control the feed motor to advance the wire electrode based on a first parameter of the welding operation; and control the power conversion circuitry to output the welding-type power to the wire electrode based on the first parameter or a second parameter of the welding operation.

Abstract: Systems and methods for auto-tuning a MIG welding process are disclosed. A welding-type power supply may include a power conversion circuitry configured to convert input power to welding-type power; and a controller configured to control the power conversion circuitry based on a plurality of operating parameters. The operating parameters may include an inductance parameter, a slope parameter, or a wet time parameter. During the welding process, in order to control the power conversion circuitry, the system may measure an output from the power conversion circuitry, and may update the inductance parameter, the slope parameter, or the wet time parameter.

Abstract: A method includes receiving data corresponding to a voltage level over time and a current level over time. The method also includes determining a first ratio corresponding to a voltage ramp percent or a voltage falling edge percent with respect to a peak in the voltage level and determining a second ratio corresponding to a current ramp ratio or a current falling edge ratio with respect to a peak in the current level. The method further includes determining, based on a comparison between the first ratio and the second ratio, whether to increment, decrement, or maintain an inductance compensation estimation value corresponding to an estimated inductance present in one or more secondary components associated with the welding operation.

Abstract: A data structure for weld programs associates configuration data for a welding system with a plurality of weld programs and weld sequence data. The data structure allows the welding system to be configured for a particular part, operator, or stage in a welding process, and to be easily reconfigured when the part, operator, or stage changes, providing improved efficiency and flexibility in operation.

Abstract: A data structure for weld programs associates configuration data for a welding system with a plurality of weld programs and weld sequence data. The data structure allows the welding system to be configured for a particular part, operator, or stage in a welding process, and to be easily reconfigured when the part, operator, or stage changes, providing improved efficiency and flexibility in operation.

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 providing a welding type power using a welding power circuit having a control input and a welding type power output, a feedback circuit and a controller connected to the control input and the feedback circuit is disclosed. The controller includes a parameter setting module and/or a process selection module that are connected to and responsive to at least one of the feedback circuit. The a process selection module can be responsive to the parameter setting module.

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 pulsed welding regime includes a peak phase in which energy is added to an electrode and a weld puddle, and a molten ball begins to detach from the electrode, followed by a dabbing phase in which current is significantly reduced to place the ball in the weld puddle with addition of little or no energy. The resulting short circuit clears and the system proceeds to a background phase. The current in the dabbing phase is lower than the current during the background phase. The process may be specifically adapted for particular welding wires, and may be particularly well suited for use with cored wires. The dabbing phase allows for lower energy to be transferred to the sheath of such wires, and resets the arc length after each pulse cycle.

Abstract: Welding wire preheating systems and methods are disclosed. An example welding method includes: receiving a signal indicative of initiation of welding process; prior to initiating a welding arc based on the received signal, controlling voltage or current applied to a welding electrode to preheat the electrode to a temperature above an ambient temperature but below a melting point of the welding electrode; monitoring feedback voltage to determine a termination of preheating; and terminating preheating prior to initiating the welding arc in accordance with a welding protocol.

Abstract: A pulsed welding regime includes a peak phase in which energy is added to an electrode and a weld puddle, and a molten ball begins to detach from the electrode, followed by a dabbing phase in which current is significantly reduced to place the ball in the weld puddle with addition of little or no energy. The resulting short circuit clears and the system proceeds to a background phase. The current in the dabbing phase is lower than the current during the background phase. The process may be specifically adapted for particular welding wires, and may be particularly well suited for use with cored wires. The dabbing phase allows for lower energy to be transferred to the sheath of such wires, and resets the arc length after each pulse cycle.

Abstract: A method and apparatus for providing welding-type power that alternates between at least a hotter and a colder process is disclosed.

Abstract: In a welding system, a preheating process is carried out prior to initiation of a welding arc, such as upon depression of a trigger or switch on a welding torch. The preheating process involves generation and application of desired currents and voltages to a welding electrode from a power supply. Preheating is continued until the welding electrode reaches a desired temperature or resistance, which may be determined by reference to an increasing voltage, a decreasing current, a peaked and declining voltage, resistance and/or power measurements, and so forth. Following preheating, a desired welding process may begin with initiation of the welding arc.

Abstract: A method and apparatus for short circuit welding is disclosed. They reduce the current prior to the short clearing by adjusting waveform parameters in response to past cycles. One or more parameter of the output is monitored and compared to one or more targets, and future waveform parameters are adjusted so that the monitored parameters are more likely to reach the one or more targets.

Abstract: A method and apparatus for starting a wire fed weld operation includes monitoring at least one of a prior run-in time, a prior run in distance, a prior run in wire feed speed, and/or whether or not there is contact at the time of a prior start. Then the wire position is controlled for a present weld operation in response to the monitored data.

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 is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.