Abstract: A welding machine includes a welding power supply that generates a welding waveform during a welding operation, an internal combustion engine, and a generator that is operatively connected to the welding power supply to supply electrical energy to the welding power supply. The generator includes a rotor shaft driven by the internal combustion engine, and an end casting located at an end of the generator opposite the internal combustion engine. A rotary screw compressor is mounted to the end casting of the generator. A clutch mechanism couples the rotor shaft to the rotary screw compressor to selectively drive the rotary screw compressor by the rotor shaft.

Abstract: A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

Abstract: A welding machine includes a welding power supply that generates a welding waveform during a welding operation, an internal combustion engine, and a generator that is operatively connected to the welding power supply to supply electrical energy to the welding power supply. The generator includes a rotor shaft driven by the internal combustion engine, and an end casting located at an end of the generator opposite the internal combustion engine. A rotary screw compressor is mounted to the end casting of the generator. A clutch mechanism couples the rotor shaft to the rotary screw compressor to selectively drive the rotary screw compressor by the rotor shaft.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: An energy storage module (ESM) is provided for connecting to a welding or cutting machine (WCM). The ESM has a controller for connecting to a communication link (CM) to communicate with the WCM when the ESM is connected to the WCM. The ESM also has a battery pack to store electrical energy and output DC electrical power to be used by the WCM, under control of the controller. Electrical input power provided to the WCM from an electrical grid or a renewable energy source during a welding or cutting operation can be supplemented or replaced by the DC electrical power from the ESM. The ESM further has regulation circuitry to regulate the DC electrical power output from the battery pack. The controller controls the regulation circuitry based on identification data received over the CM from the WCM to regulate the DC electrical power to be electrically compatible with the WCM.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: Embodiments of systems and methods to relate welding wire to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a consumable source of welding wire, and at least one of a weight status, indicating a change in weight, or an energization status, indicating an energization state, of the consumable source of welding wire. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source, and an activation status indicating an activation state of the welding power source. The server computer is configured to match the welding power source to the consumable source of welding wire based on at least the first data and the second data.

Abstract: Systems and methods for welding, and more specifically to a controller with the capability to power and control a welder and an associated workpiece heater. Exemplary systems and methods may further control a welder and associated heater according to feedback from the welder and/or heater.

Abstract: Systems and methods for welding, and more specifically to a power supply with the capability to power and control a welder and an associated workpiece heater. Exemplary systems and methods may further control a welder and associated heater according to feedback from the welder and/or heater.

Abstract: A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

Abstract: A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: Embodiments of modular-based power supply systems to support welding or cutting operations are disclosed. One embodiment includes a module rack having multiple slots configured to accept electrical input power from a single power drop within a welding or cutting environment. Multiple power supply modules are provided that are configured to be inserted into and withdrawn from the multiple slots. Each power supply module is configured to accept an electrical AC input derived from the electrical input power and provide an electrical DC output. The module rack is configured to support reconfigurable parallel electrical connections of subsets of the power supply modules. Each subset is configured to electrically connect to an output power supply stage to provide a dynamic waveform-controlled welding or cutting electrical signal to support generation of a single arc between an electrode and a workpiece.

Abstract: Embodiments of systems and methods to relate a human operator to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a welding helmet within a welding environment, and a triggering status indicating a triggering of an arc detection sensor of the welding helmet due to initiation of a welding arc. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source within the welding environment, and an activation status indicating an activation of the welding power source. The server computer is configured to match the welding power source to a human operator using the welding helmet based on at least the first data and the second data.

Abstract: Embodiments of modular-based power supply systems to support welding or cutting operations are disclosed. One embodiment includes a module rack having multiple slots configured to accept electrical input power from a single power drop within a welding or cutting environment. Multiple power supply modules are provided that are configured to be inserted into and withdrawn from the multiple slots. Each power supply module is configured to accept an electrical AC input derived from the electrical input power and provide an electrical DC output. The module rack is configured to support reconfigurable parallel electrical connections of subsets of the power supply modules. Each subset is configured to electrically connect to an output power supply stage to provide a dynamic waveform-controlled welding or cutting electrical signal to support generation of a single arc between an electrode and a workpiece.

Abstract: Embodiments of systems and methods to relate a human operator to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a welding helmet within a welding environment, and a triggering status indicating a triggering of an arc detection sensor of the welding helmet due to initiation of a welding arc. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source within the welding environment, and an activation status indicating an activation of the welding power source. The server computer is configured to match the welding power source to a human operator using the welding helmet based on at least the first data and the second data.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: Systems and methods for selecting a welding output waveform based on characterizing a welding circuit output path with respect to its electrical characteristics. At least one electrical characteristic (e.g., inductance, resistance) of a welding output circuit path connected to a welding power source is determined. A welding output waveform is selected from a plurality of welding output waveforms based on the determined electrical characteristics. As a result, the selected welding output waveform is matched to the welding output circuit path electrical characteristics to provide superior welding performance.

Abstract: Embodiments of systems and methods to relate welding wire to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a consumable source of welding wire, and at least one of a weight status, indicating a change in weight, or an energization status, indicating an energization state, of the consumable source of welding wire. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source, and an activation status indicating an activation state of the welding power source. The server computer is configured to match the welding power source to the consumable source of welding wire based on at least the first data and the second data.

Abstract: Embodiments of systems and methods to relate welding wire to a welding power source are disclosed. One embodiment is a wire docking station for use in a welding environment. The wire docking station includes a loading platform configured to accept a replaceable source of consumable welding wire, and a scale configured to generate a weight status of the source of consumable welding wire when docked with the loading platform. The wire docking station also includes a communication module and a contact mechanism configured to form an electrical connection between the source of consumable welding wire and the communication module. The communication module includes a transmitter configured to transmit docking station data as current draw pulses to a welding power source over the consumable welding wire of the source of consumable welding wire.