Abstract: A welding or cutting system is provided using a performance module which monitors the real-time performance of a welding or cutting system and displays this information on a user interface on the system. Other embodiments of the system also include a cost calculation function in which a cost of the welding or cutting operation is calculated.

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: A system and method are provided for recognizing peripheral devices coupled to a welding power source and changing operational settings of the welding power source based the recognized peripheral. Systems and methods allow for remote recognition of the type and capabilities of a peripheral device using handshake communication signals.

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: A welding or cutting system is provided using a performance module which monitors the real-time performance of a welding or cutting system and displays this information on a user interface on the system. Other embodiments of the system also include a cost calculation function in which a cost of the welding or cutting operation is calculated.

Abstract: A production monitoring system has a production monitoring server, a network communication system, production monitoring data store, and production monitoring module. The system is configured to receive, from multiple construction locations, information relating to weld locations, welding parameters, and inspection status for individual welds. Welding information is stored within data stores and is retrieved on request to generate inspection reports containing weld locations, welding parameters, and inspection status for individual welds. Inspection reports can be delivered remotely to a plurality of electronic devices and may contain data from x-ray or ultrasound weld inspections. Weld location may be generated by GPS or by one or more location sensors. The system can receive updated inspection information and update the corresponding information in the data store. Inspection reports can incorporate welding information within a two-dimensional map or three-dimensional model of a construction location.

Abstract: A welding or cutting system is provided using a performance module which monitors the real-time performance of a welding or cutting system and displays this information on a user interface on the system. Other embodiments of the system also include a cost calculation function in which a cost of the welding or cutting operation is calculated.

Abstract: Systems and methods of the present invention are directed to welding systems having a welding power supply and wire feeder, where the power supply and wire feeder communicate over the welding power cables. In exemplary embodiments, the wire feeder communicates with the power supply over the welding cables using current draw pulses which are generated and recognized by the power supply. Similarly, the power supply generates voltage pulses which are transmitted over the welding power cables and recognized by the wire feeder.

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 welding or cutting system is provided using an interleaved buck-boost stage which dynamically controls power factor correction and operation of the interleaved buck-boost modules to optimize efficiency and operation of the welding system.

Abstract: A powered air-purifying respirator helmet system includes a helmet having a lens. A photovoltaic power source is mounted on the helmet. A trunk-worn blower is separate from the helmet. The trunk-worn blower includes a fan and a rechargeable battery operably connected to power the fan. A flexible air-electrical conductor interconnects the trunk-worn blower and the helmet to simultaneously supply both pressurizing air to the helmet and electrical energy generated by the photovoltaic power source on the helmet to the trunk-worn blower.

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: A welding or cutting system is provided using a performance module which monitors the real-time performance of a welding or cutting system and displays this information on a user interface on the system. Other embodiments of the system also include a cost calculation function in which a cost of the welding or cutting operation is calculated.

Abstract: A welding or cutting system is provided using an interleaved buck-boost stage which dynamically controls power factor correction and operation of the interleaved buck-boost modules to optimize efficiency and operation of the welding system.

Abstract: A welding or cutting power system having a signal conversion module, which receives an AC input signal and converts the AC input signal to an output signal. The output signal is output to a load. The signal conversion module comprises at least one component which increases in temperature during operation of the signal conversion module, and a cooling fan is used to cool the at least one component of the signal conversion module. A motor is coupled to the fan to operate said cooling fan. The power system also includes a temperature sensor, which senses a temperature of the at least one component and generates a temperature feedback signal. The system further includes a fan controller that controls a rotational speed of the fan based on at least the temperature feedback signal.

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: 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: A heat dissipation platform for output switches of an inverter power source of an electric arc welder where the platform comprises a conductive plate with first and second parallel surfaces and a plurality of parallel heat pipes embedded between the surfaces and extending in a given direction and the switches are mounted on the first surface and are closely spaced from each other in the given direction of the heat pipes.

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, a network of switches switched at a high frequency with a given duty cycle to convert the input into a first internal AC signal, an isolation transformer with a primary winding driven by the first internal high frequency AC signal and a secondary winding for creating a second internal high frequency AC signal and a rectifier to convert the second internal AC signal into a second DC output signal of the second stage, with a magnitude related to the duty cycle of the switches; and, a third stage to convert the second DC output signal to a welding output for welding wherein the input stage has a regulated DC to DC converter with a boost power switch having an active soft switching circuit.

Abstract: Power sources are disclosed for electric arc welding or cutting processes, in which an interleaved multiphase switching converter is provided with a plurality of converter power circuits to convert a DC signal to a regulated signal suitable for welding.