Abstract: Methods and devices for control for an automated welding system are provided. Disclosed control methods may include receiving a data set including one or more features of a joint to be welded and receiving a weld procedure for the joint to be welded. The weld procedure for the joint is determined based on a sample virtual weld performed by an operator, a stored procedure developed for a substantially similar weld joint, or a combination thereof. The method may further include determining one or more desired changes to the weld procedure based on the received features of the joint to be welded and generating an updated weld procedure by altering one or more parameters of the received weld procedure in accordance with the one or more desired changes, wherein the one or more parameters are included within a predetermined allowable data set.

Abstract: Methods and apparatus to provide a consistent electrode state for welding, an example welding-type system includes: a first wire drive to feed an electrode wire through a welding torch; a bidirectional assisting wire drive to advance the electrode wire from a wire supply to the first wire drive; a tension-compression detector to detect a first tension-compression state of the electrode wire; and one or more motor controllers to control the first wire drive and the assisting wire drive to put the electrode wire in a predetermined position relative to the welding torch by: controlling the first wire drive to hold the electrode wire; and controlling the assisting wire drive to advance or retract the electrode wire based on the first tension-compression state to put the electrode wire in a second tension-compression state.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: A welding training system includes one or more welding operator device which provides positional feedback relevant to a quality weld. The positional feedback is analyzed and, when the positional feedback is outside of a predetermined range, a signal is provided to the welding operator. In one embodiment, tactile feedback is provided in a welding gun.

Abstract: Portable, wearable or integrate-able devices may be used in detecting gestures or motions by operators of welding systems, and performing actions based thereon. The detection may be performed using sensors (e.g., MEMS or muscle sensors), which generate sensory data. The detected gestures or motions may be processed and translated into corresponding actions or commands, which may be handled directly or communicated to other devices in the welding systems. The actions or commands may comprise welding actions/commands, which are configured for controlling a particular component used during welding operations, and/or gesture-related actions/commands, which are configured for controlling gesture-related components and/or operations. Feedback is provided to the operator, such as to acknowledge or validate detection of the gestures, to identify the corresponding action or command, and to complete the identified action or command. The feedback may be non-visual feedback, such as haptic or audio feedback.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: A method and apparatus for providing a welding-type power includes a housing with an auxiliary power mount, and a welding type power circuit. A controller, a control power circuit, and an auxiliary power module are disposed in the housing. The auxiliary power module/circuit is mounted to the auxiliary power mount. A standard power receptacle is connected to the auxiliary power module. At least one wiring harness connects the welding type power circuit to the auxiliary power module/circuit, which is the only electrical connection between the auxiliary power circuit and the welding type power circuit. The auxiliary power is electrically isolated from the input power and the welding type power.

Abstract: Methods and devices for control for an automated welding system are provided. Disclosed control methods may include receiving a data set including one or more features of a joint to be welded and receiving a weld procedure for the joint to be welded. The weld procedure for the joint is determined based on a sample virtual weld performed by an operator, a stored procedure developed for a substantially similar weld joint, or a combination thereof. The method may further include determining one or more desired changes to the weld procedure based on the received features of the joint to be welded and generating an updated weld procedure by altering one or more parameters of the received weld procedure in accordance with the one or more desired changes, wherein the one or more parameters are included within a predetermined allowable data set.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: A method and apparatus for arc welding, particularly starting an arc is disclosed. A welding power source that provides a welding current to an electrode and a workpiece includes a source of welding current having an inductor. The inductor and current source are connected to a pair of outputs, such as the output studs, and form a welding current path including the source of current, the output inductor, the outputs and the electrode and workpiece. A source of a high frequency voltage, such as a high frequency coupling coil is included in the welding current path. An arc starting circuit provides a controllable current path for current flow in the inductor prior to the application of high frequency voltage. The arc starting current path is not the welding current path.