Abstract: A welding system includes one or more sensors configured to detect data relating to one or more arc parameters for the welding system during a weld performed by the welding system. The welding system also includes control circuitry configured to receive the data corresponding to the one or more arc parameters from the one or more sensors, time synchronize the data corresponding to the one or more arc parameters with data relating to one or more welding parameters over a time period for the weld, present the data corresponding to the one or more arc parameters graphically over the time period via a user-viewable screen during the weld, and present the data corresponding to the one or more welding parameters graphically over the time period via the user-viewable screen during the weld.

Abstract: A welding system includes one or more cameras and a controller coupled to the one or more cameras. The one or more cameras are configured to detect a plurality of sets of visual markers of a welding device, where each each set is oriented in a respective marker direction. The controller is configured to determine one or more marker directions of one or more respective sets of visual markers based on a detected set of visual markers, to select one of the sets of visual markers as a tracked set of visual markers based at least in part on a determined marker direction of the tracked set of visual markers, to associate a rigid body model to the tracked set of visual markers, and to determine a position and an orientation of the welding device based on the associated rigid body model of the tracked set of visual markers.

Abstract: A system includes one or more sets of reflective visual markers, a light source configured to emit light, and a controller communicatively coupled to the light source. Each set of reflective visual markers is coupled to a component of a welding system. Each reflective visual marker is configured to reflect the emitted light received from the light source towards one or more cameras. The controller is configured to control illumination settings of the light source based at least in part on a status of the welding system being utilized to perform a live-arc welding operation.

Abstract: A method includes receiving welding data corresponding to a welding session completed with a welding system, receiving a selected location from an operator, and displaying on a display one or more quality characteristics of the welding session corresponding to the selected location. The welding data includes welding parameters and quality characteristics corresponding to a plurality of points along a path of the welding session. The welding parameters include a work angle of a welding torch, a travel angle of the welding torch, a contact tip to work distance, a travel speed of the welding torch along the path of the welding session, an aim of the welding torch, or any combination thereof. The quality characteristics include porosity, undercut, spatter, underfill, overfill, or any combination thereof. The selected location corresponds to a point of the plurality of points along the path of the welding session.

Abstract: A system including a base component configured to be detected by one or more cameras of a welding system. The base component includes a thermally insulating layer coupled to the base component, a first set of three or more visual markers coupled to the thermally insulating layer on a first face of the base component, and a cover layer disposed on the thermally insulating layer on at least the first face of the base component. An exterior surface of the cover layer is less reflective of visible light or infrared light than the first set of three or more visual markers.

Abstract: A system includes a welding device, one or more cameras, and a controller coupled to the one or more cameras. The welding device includes a first set of visual markers oriented in a first direction and a second set of visual markers oriented in a second direction. Each set of visual markers includes at least three visual markers. The one or more cameras are configured to observe the first set of visual markers when the first direction is directed toward the one or more cameras, and to observe the second set of visual markers when the second direction is directed toward the one or more cameras. The controller is configured to track a position and an orientation of the welding device based at least in part on detection of a threshold quantity of the first set of visual markers or the threshold quantity of the second set of visual markers.

Abstract: A method includes calibrating a first path of a joint of a workpiece of a welding system relative to a component, determining a first set of welding parameters of a welding torch based at least in part on a tracked position and a tracked orientation of the welding torch along the first path of the joint during a first live-arc welding operation, calibrating a second path of the joint of the workpiece relative to the component, determining a second set of welding parameters of the welding torch based at least in part the tracked position and orientation of the welding torch along the second path of the joint during a second live-arc welding operation, and displaying at least one of the first and second sets of welding parameters on a display. The second path is disposed at least partially over the first path.

Abstract: A method including determining an orientation of a display of a welding torch relative to a joint of a workpiece, displaying, on the display of the welding torch during a welding operation, a graphical representation of a welding parameter in relation to a predetermined threshold range for the welding parameter as a position of the welding torch changes, the orientation of the welding torch changes, a movement of the welding torch changes, or some combination thereof, and rotating the graphical representation of the welding parameter based at least in part on the determined orientation of the display of the welding torch relative to the joint. The graphical representation of the welding parameter is associated with the position of the welding torch relative to the joint, the orientation of the welding torch relative to the joint, the movement of the welding torch relative to the joint, or some combination thereof.

Abstract: An air barrier that prevents entrainment of surrounding air from the welding environment into the welding helmet is provided. The barrier for the welding helmet contains a flexible curtain, front and rear edges, and means for securing the front edge of the curtain adjacent to the rear edge of the helmet. The flexible curtain may be made of fire-resistant and flexible molded material. The air barrier may be permanently secured to or removable from the welding helmet. The invention may be used in conjunction with a variety of ventilation and cooling systems, including small units that mount on or in welding helmets, as well as more elaborate blowing systems partially carried by the welder.

Abstract: A welding system includes a first position detection system, a second position detection system independent of the first position detection system, and a controller coupled to the first and second position detection systems. The first position detection system is configured to generate a first output corresponding to a first position and a first orientation of a welding torch during a welding session for a weld. The second position detection system is configured to generate a second output corresponding to a second position and a second orientation of the welding torch during the welding session. The controller is configured to determine welding parameters during the welding session based at least in part on the first output, the second output, or any combination thereof. The welding parameters may include a work angle, a travel angle, a contact tip to work distance, a travel speed, an aim, or any combination thereof.

Abstract: An embodiment of a system includes a marking tool configured to apply one or more markers on a first surface of a workpiece for a live welding session. The one or more markers have known geometric properties that may facilitate determination of the first surface and a weld joint. An embodiment of a method includes applying a first set of one or more markers to a first surface of a workpiece, detecting the applied first set of one or more markers with a camera, and determining, via processing circuitry coupled to the camera, at least one of the first surface of the workpiece and a weld joint based at least in part on the detected first set of one or more markers.

Abstract: A method of managing welding data, including receiving, via a network, welding data from a data storage system, populating, via a processor, a user viewable dashboard page with one or more user input controls, receiving a user input via the user viewable dashboard page, and populating, via the processor, the user viewable dashboard page with graphical indicia representative of one or more subsets of welding data corresponding to the received user input. The welding data includes welding parameters associated with welding sessions performed by a plurality of welding operators. The user input controls include filter criteria, a search control, or any combination thereof. Each filter criterion of the filter criteria corresponds to a respective subset of the welding data. The user input includes a selection of one or more filter criteria from a user, a search string input via the search control, or any combination thereof.

Abstract: A welding system including a processor configured to receive a first set of welding data of a live welding session corresponding to welding parameters, arc parameters, or any combination thereof, a memory configured to store the received first set of welding data, and an operator identification system coupled to the processor and to the memory. The operator identification system includes an input device configured to receive a first identifier input from a first operator that performs the welding session and a second identifier input from a second operator. The operator identification system is configured to determine an identity of the first operator based at least in part on the first identifier input, to verify the identity of the first operator based at least in part on the second identifier input, and to associate the received first set of welding data with the first identifier input.

Abstract: A method of operating a welding system includes receiving welding data corresponding to a welding session for a weld, receiving a location selection from an operator, and displaying on a display a graphical representation of welding parameters of the welding selection corresponding to the location selection. The welding data includes welding parameters, including a work angle of a welding torch, a travel angle of the welding torch, a contact tip to work distance, a travel speed of the welding torch along a path of the weld, an aim of the welding torch, or any combination thereof. The location selection corresponds to a point along the path of the weld traversed by the welding torch.

Abstract: A welding system including a helmet having one or more sensing devices configured to detect a position and an orientation of a welding torch relative to a workpiece during performance of a welding session, and a controller coupled to the one or more sensing devices and configured to receive arc parameters corresponding to the performance of the welding session.

Abstract: A weld training system is provided. The weld training system includes a welding torch configured to perform a welding procedure and a mobile device coupled to the welding torch. The mobile device is configured to detect, via one or more sensors, dynamic position or orientation information of the welding torch during the welding procedure to determine one or more operating parameters of the welding procedure. The mobile device is also configured to display a welding environment based at least in part on the one or more operating parameters.

Abstract: A method and system for controlling ventilation in a welding helmet is provided. The invention may be adapted to a wide variety of system types, and may reduce or eliminate the need for a shroud or barrier around the head and neck of the welder, of the type used in PAPR systems. The airflow system includes forward and rearward air streams, directed onto the face of the welder, onto the top of the head of the welder, and toward the back of the head of the welder. The air streams help to cool the welder, provide a fresh source of air for breathing, and create a positive pressure system that reduces or excludes entrainment of contaminated external air into the forwardly directed air flow. Certain embodiments may include streams that are filtered, split or redirected via deflectors and conduits to achieve the aforementioned goals.

Abstract: A welding system includes a welding power source having a user interface disposed thereon and a weld controller disposed therein and being adapted to generate a welding power output for use in a welding operation. The welding system also includes a personal computer having control circuitry disposed therein and being removably interfaced with the welding power source via a docking mechanism. When the personal computer is docked within the docking mechanism, the personal computer is enabled for receiving operator input, and the control circuitry communicates with the weld controller to coordinate control of a welding operation in accordance with the operator input.

Abstract: A weld recording system mounted in or on a welding helmet is provided. The weld recording system includes a camera assembly unit, a power supply unit, a processor, and removable memory. The weld recording system interfaces with lens control circuitry, an optical sensor, a welding power supply, and a helmet position sensor. Logic is provided for the triggering and recording of video and audio signals, which are eventually stored in a file for future reference. Transmission of signals from one or more welders to a monitoring station for eventual display is presented. An image processing algorithm is provided to combine multiple images with varied exposure times into a visual image of the weld and its surroundings.

Abstract: A system enables transmitting a torch angle and/or a torch-to-workpiece distance error to a welding operator when these parameters are outside of a preset optimal range via real time audio cues. Weld characteristics are communicated via audio signals, which indicate to the welding operator the direction and severity of the torch angle error. Audio cues, such as pulsed or continuous tones, are used to communicate torch-to-workpiece distance to the welding operator.