Abstract: A welding device for remotely controlling welding power supply settings is provided. One embodiment of the welding device includes a welding pendant having a control panel configured to control a plurality of settings of a welding power supply. The control panel is not part of the welding power supply and the plurality of settings includes a welding current output by the welding power supply. The welding pendant also includes a welding power input configured to receive welding power and data from the welding power supply via a welding power cable. The welding power is combined with the data such that the data is provided over the welding power cable.

Abstract: A resistance welding device includes a power source in order to provide a welding current for welding workpieces, a welding gun with two gun arms having one electrode each in order to impress the welding current into the workpieces. The power source includes a heavy-current transformer with at least one primary winding and at least one secondary winding with center tapping, a synchronous rectifier connected with the secondary winding and including circuit elements, and a circuit for actuating the circuit elements of the synchronous rectifier. For reduction of losses and improvement of efficiency, the power source is arranged at the welding gun and the power source includes at least four contacts forming a multi-point contacting, wherein two first contacts of one polarity are connected to one gun arm and two additional contacts of opposite polarity are connected to the other gun arm.

Abstract: A telecommunications system for a programmable logic controller (PLC) includes: a master module comprising a transmitter and a receiver; one or more slave modules configured to receive signals transmitted from the transmitter and transmit signals to the receiver in response to the transmitted signals; a signal conversion module configured to convert the signals transmitted between the master module and the slave modules into digital signals; a control module configured to control the signal conversion module and to determine whether there is an error in the signals transmitted between the master module and the slave modules based on the digital signals; a display module configured to display a result of the determination by the control module.

Abstract: A resistance spot welding device that joins predetermined parts to be welded includes: a storage configured to store a time variation of an instantaneous amount of heat generated per unit volume and a cumulative amount of heat generated per unit volume in test welding that precedes actual welding; and an adaptive controller and an electrode force controller configured to, in the case where the time variation of the instantaneous amount of heat generated per unit volume in the actual welding differs from a time variation curve stored as the target value, respectively control the current or a voltage during current passage and the electrode force to the parts to be welded to compensate for the difference within a remaining welding time so that the cumulative amount of heat generated per unit volume in the actual welding matches the cumulative amount of heat generated per unit volume stored in the storage.

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: The invention described herein generally pertains to a system and method for evaluating one or more conditions or preliminary weld condition related to a welding system and/or method that utilizes a welding sequence to perform two or more welds with respective welding schedules. In an embodiment, an operator registration is provided that verifies the operator and identifies welding sequences to which the operator is authorized to perform. In another embodiment, one or more fixture locations are monitored to determine whether a workpiece is accurately configured prior to a welding operation. In still another embodiment, locations on a workpiece can be displayed to assist an operator in performing two or more welds utilizing a welding sequence. Moreover, a wireless system communications a data signal to a welding work cell in which such data is used to identify a welding sequence.

Abstract: A cylinder of a combustor includes a cylinder body inside of which combustion gas flows, a jacket plate that covers the cylinder body from the outside and forms a fluid space into which high-pressure fluid flows between an inner peripheral surface of the jacket plate and an outer peripheral surface of the cylinder body, and a rib that connects the cylinder body and the jacket plate. The rib is connected to the cylinder body by a cylinder side end portion on the cylinder body side in a radial direction with respect to an axis of the cylinder body being welded from both sides in an axial direction of the axis. The rib is connected to the jacket plate by a jacket side end portion on the jacket plate side in the radial direction being welded from both sides in the axial direction.

Abstract: A resistance spot welding system includes a calculation unit that calculate and store a time variation of an instantaneous amount of heat generated, a division unit that divides a current pattern into a plurality of steps and stores a time variation of the instantaneous amount of heat generated and a cumulative amount of heat generated for each step as a target value, and an adaptive control unit that starts welding upon subsequent actual welding using, as a standard, a time variation curve of the instantaneous amount of heat generated that is stored as the target value, and adjusts welding current and voltage during welding, when a time variation amount of an instantaneous amount of heat generated deviates during any step from the time variation curve by a difference, so as to compensate for the difference during a remaining welding time in the step.

Abstract: Resistance spot welding is performed on a combination of overlapping steel sheets including at least one steel sheet that has, on a surface thereof, a coated layer with zinc as a main component, by (1) starting electric current passage in a state satisfying 0.9×t?L?1.1×t; and (2) dividing electric current into main current and initial current that precedes the main current and is two-step current, setting a current value I1 during current in a first step of the initial current to satisfy Im×1.1?I1?15.0 kA with respect to a current value Im during the main current, and setting a current value I2 in the subsequent second step to no current or low current satisfying 0?I2?Im×0.7.

Abstract: A method and an apparatus for determining the temporal curve of the voltage (ue(t)) at the electrodes (3) of a spot welding gun (1) during a spot welding process as an indicator of the welding quality, wherein the electrodes (3) are fastened to gun arms (2) that can be moved relative to each other are provided. The apparatus includes a device (9) for measuring a measuring voltage (um(t)) between the electrodes (3), that measuring device (9) being connected to measuring leads (6) extending along the gun arms (2), and further includes a compensating coil (7) for measuring a compensating voltage (uk(t)) for compensating measuring errors within measuring leads.

Abstract: A welding process for the welding of aluminum includes a force sensor measuring a force between two welding electrodes on aluminum elements to be welded and transmitting its measured values to a welding control. Until the elapse of a set welding time, the welding control calculates and stores at least one absolute value and/or at least one increase in the measured force. The welding control compares the measured absolute value and/or the increase in the measured force with a reference value and/or a reference curve and calculates a control deviation from the comparison. After the elapse of the set welding time, the welding control subjects the welding electrodes to a constant current during a welding time extension that follows the set welding time, dependent on a magnitude of the control deviation that is measured at the point in time of the elapse and/or during the set welding time.

Abstract: In some aspects, a relay control device includes a processor and a timer. The processor is electrically connectable to a relay that controls current flow to a load device. The processor causes the relay to be actuated at a first point in time so that a current flows to the load device. The processor determines an actuation duration for the relay from a measurement of the load current that is obtained with a current sense component. The processor determines a frequency of an input voltage or current from the measured load current. The processor synchronizes the timer with this frequency and identifies a zero-crossing point for a second load current based on the synchronized timer. The processor subsequently causes the relay to be actuated at a time that is offset from the zero-crossing point by the actuation duration.

Abstract: A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

Abstract: In a resistance spot welding method, test welding and actual welding in which a current pattern is divided into two or more steps are performed. In the test welding, a constant current of a different value is passed in each step, and a time variation of an instantaneous amount of heat generated per unit volume and a cumulative amount of heat generated per unit volume are stored as a target value. In the subsequent actual welding, when a time variation amount of an instantaneous amount of heat generated per unit volume deviates during any step from the results of the test welding, a current passage amount is controlled to compensate for the difference during a remaining welding time in the step. In the test welding, 0.3×Ix?Ia<Ix, where Ia is the current in the first step, and Ix is the current in second and subsequent steps.

Abstract: Distance to the upper face of workpieces W sandwiched between electrode rollers 15 and 16 is measured by a range sensor 41 that has a predetermined positional relationship with the electrode rollers 15 and 16 (STEPs 1, 3). Correction is made based on the distance found by the range sensor 41 by moving the pair of electrode rollers 15, 16 with reference to the workpieces W so that an angle Rx between a straight line L0 connecting centers of the pair of electrode rollers 15, 16 and the surface of the plurality of workpieces W is preset angle (STEP 5).

Abstract: A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

Abstract: There is provided a system and method for quick identification and selection of torch processes based on a profile scheme. In an illustrated embodiment, a profile selectable via a one-click process may define operational parameters for one or more torch processes. Multiple profiles may be identified by corresponding labels that are visible on the face of the system. Furthermore, in an illustrated embodiment, the profiles and associated torch processes may be automatically stored in the system upon user configuration of the operational parameters. For example, in one embodiment, the user may select a profile and configure a welding process. Upon changing an operational parameter, it may be automatically saved to the selected profile and process. Reselection of that profile may recall the last used process and its associated parameters. The operational parameters of other configured processes may then be retrieved by selecting the desired process within the selected profile.

Abstract: This application provides methods and apparatus for controlling aspects of a synchronous rectifier power converter. In an example, an apparatus can include a minimum duty cycle control circuit configured to receive first control signals for one or more switches associated with the synchronous rectifier power converter, to compare a duty cycle of the first control signals to a minimum duty cycle threshold, and to provide second control signals having at least the minimum duty cycle for an active snubber switch of the synchronous rectifier power converter.

Abstract: A current diffusion bonding apparatus (1) includes upper and lower electrodes (11, 12), which sandwich members to be bonded (M, M) and which are electrically conductible with the members to be bonded (M, M); a power supply unit (20), which supplies a current to the electrodes (11, 12); and a pressurizing unit (30), which applies a pressure to bonding surfaces S. If a temperature T detected by a temperature sensor (45) is a first set temperature T1 or lower, the pressurizing unit (30) applies a pressure to the bonding surfaces S while restricting the displacement of the members to be bonded (M, M), and if the temperature T exceeds the first set temperature T1, the pressurizing unit (30) applies a pressure based on the elastic force of a spring (35d), which elastically deforms according to the displacement of the members to be bonded (M, M), to the bonding surfaces S.

Abstract: A welding device for a production system having a welding tool and a control device operatively connected to the welding tool. The control device can be configured to control the control the welding tool to connect at least two components with a welded connection with reference to a first parameter. The first parameter defines the welded connection. The control device can be furthered configured to access the first parameter for the welded connection with reference to a hierarchy, wherein the hierarchy identifies a second parameter assigned to the first parameter and the second parameter contains a third parameter, wherein the second parameter defines a welding task and the third parameter defines a first combination of values.

Abstract: A method for determining the quantity of fuel flowing through a fuel injector. The fuel injector has an electric heating device for heating the fuel and a temperature-measuring device for measuring the temperature of the heated fuel. The method includes (a) applying a predetermined electrical heating power to the electric heating device, (b) measuring an increase in the temperature of the fuel as a consequence of the heating power, and (c) determining the quantity of fuel flowing through the fuel injector on the basis of the applied electrical heating power and the measured increase in the temperature. A method for equalizing the fuel feed at at least two cylinders of an internal combustion engine utilizes the method for determining the quantity of fuel flowing through a fuel injector. An engine controller and a computer program carry out the specified methods.

Abstract: A constant current control power supply of an embodiment of the present invention includes a switching regulator that includes a switching circuit having a switching device and a rectifier device, a smoothing circuit having reactors and capacitors, a current detection circuit, and a control circuit, for outputting a constant current in accordance with a command value from a controller. When ON indicates a case where the command value commands an output of a higher current than a predetermined value and OFF indicates a case where the command value commands an output of a lower current than the predetermined value, on condition that a pulse operation alternating between the ON and the OFF is inputted, the control circuit amplifies a variation in the command value by a predetermined amplification factor and adds the amplified variation to the command value, and attenuates the added variation with a predetermined time constant.

Abstract: A motor drive includes an electromagnetic connector for connecting an alternating current (AC) power source to an AC/DC conversion unit or disconnecting therefrom, a DC link unit, a DC/AC conversion unit for converting smoothed direct current voltage to AC voltage, a DC link voltage detection unit for measuring voltage of the DC link unit, and a control unit. The control unit includes a time measurement unit for measuring elapsed time since switching by the electromagnetic connector, and a welding judgment unit for judging that the electromagnetic connector is welded, provided that the difference between voltage between terminals of the DC link unit after charging the DC link unit and voltage between the terminals of the DC link unit after predetermined time has elapsed since disconnecting the AC power source from the AC/DC conversion unit, after the charge of the DC link unit, is less than a predetermined voltage level.

Abstract: There are provided a spot welding apparatus and a spot welding method. A workpiece is clamped between a combination of a second welding electrode and a receiving unit that abut against a thinner plate, and a first welding electrode that abuts against a second thicker plate, a pressure is applied to the workpiece by the first welding electrode, and a current is passed between the welding electrodes. Consequently, a satisfactory nugget is formed over from the thinner plate to the second thicker plate. Similarly, a workpiece is clamped between a combination of the first welding electrode and the receiving unit that abut against a thinner plate, and the second welding electrode that abuts against a second thicker plate, a pressure is applied to the workpiece by the second welding electrode. Consequently, a satisfactory nugget is formed over from the thinner plate to the second thicker plate.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A method for controlling a welder including a fusible electrode stores the values of the welding parameters required for a welding process in a storage device and saves the values as so-called characteristic curves through at least one support point per characteristic curve. A working point is set by a value for the heat input into a workpiece and a value for the wire feed speed. Upon adjustment of any of the values to a welding application the other value is kept constant by a calculation method designed such that a plurality of characteristic curves that are compatible with one another are combined to form a characteristic curve field per welding process and the welding parameters of all support points of the characteristic curves of the characteristic curve field are saved according to defined values of specific welding parameters.

Abstract: Provided is a method of resistance spot welding of welding a sheet set including a high strength steel sheet with which a high joint strength can be achieved even for a high Ceq material. A method of resistance spot welding a sheet set of two or more lapped steel sheets by weld the sheet set while clamping and pressing the sheet set between a pair of welding electrodes includes a first welding step of applying an weld current Im (kA) and forming a nugget having a nugget diameter d (mm) that satisfies the following inequality (1); a cooling step, subsequent to the foregoing first welding, of cooling the sheet set while continuing to press the sheet set; and a second welding step of performing two-step welding, 3×?tm?d?6×?tm??(1), where tm is the thickness (mm) of the thinnest one of the foregoing two or more steel sheets.

Abstract: An electric resistance welding operation management device manages a welding operation during manufacture of electric resistance welded steel pipe, in which heat is input to a steel plate, that is being conveyed along a specific conveyance direction and formed into a circular tube shape while pressing side faces of the metal plate with a pair of squeeze rolls, to weld together two circumferential direction edge portions of the metal plate converging in a V-shape. The electric resistance welding operation management device includes an image input section that inputs plural images and each including a Vee convergence region of the steel plate. The electric resistance welding operation management device includes a welding point position derivation section that derives the position of a welding point.

Abstract: A probeless energy delivery controller for a resistance spot welding system includes a power supply module that generates a first current and a power delivery module configured to generate a second current from the first current. The current is delivered to a first electrode and a second electrode that have at least two weld pieces interposed there-between. As the current flows through the weld pieces, the resistance and temperature of the weld pieces increase such that the weld pieces melt. The system further includes a voltage control module that receives a current reading indicating a value of the second current, estimates a resistance of the weld pieces based on the value of the second current, and determines a phase angle for setting a voltage outputted by the power supply module based on the estimated resistance and a power profile. The power supply module generates the first current based on the phase angle.

Abstract: Welding power is generated by first generating two different current waveforms, and comparing the waveform values for control intervals to select which waveform provides the greater current. The waveforms are for different transfer modes, such as one for a pulsed arc portion, and another for a short-circuit transfer mode or for short-circuit clearing. The waveforms may be programmed by settings in a state machine. A balance or relative prioritization in the comparison may be influenced by user inputs. The resulting hybrid process has aspects of both spray transfer and short-circuit transfer modes.

Abstract: A heating device for heating an optical fiber reinforcing member includes fiber holders to hold optical fibers covered with the reinforcing member at a fusion-spliced portion, a heater to heat the reinforcing member, a power supply unit to apply a voltage to the heater, and a controller to control the application of a voltage from the power supply unit to the heater. The controller includes a detecting unit that detects a parameter for determining the amount of heat generation of the heater, a storage unit that stores a plurality of heating conditions that vary depending on the parameter value, and a condition instruction unit that selects any of the plurality of heating conditions in accordance with the parameter value detected by the detecting unit and instructs the power supply unit to apply a voltage to the heater on the basis of the selected heating condition.

Abstract: The disclosure describes a system that uses an active filter connected to phases of a three-phase power grid in parallel with a resistance welding apparatus in order to bring an input current of a welding converter closer to a sinusoidal shape.

Abstract: A method of measuring weld thermal response as a function of time during the production of a resistance weld includes monitoring a first parameter responsive to a change in an electrode mechanical load on workpieces welded together with respect to the electrode mechanical load applied prior to application of the heat, monitoring a second parameter responsive to a change in position of linkage applying the electrode load with respect to linkage position prior to application of the heat, and processing a composite of the first parameter and the second parameter to produce a derived measurement representative of the thermal response of the weld. Electrode force and electrode current are also monitored via sensors and measurements calibrated to provide more accurate information during the welding process.

Abstract: This invention relates to an apparatus and method for output current control in an Industrial Process Control System, The output module comprises two management units each of which calculates the current demand for the module independently from one another. One management unit controls an output current controller whilst the other unit monitors the current produced by the output current controller against an independently calculated demand. The output module has multiple output modules. However rather than one module providing a backup for the other modules, or alternating between use of each module, in normal operation, each module provides a portion of the required output current, the total output current being equal to the sum of the currents output by each module. In the event of failure on one of the modules, the other module or modules switch to providing the total current required.

Abstract: There is provided a spot welding apparatus. The apparatus includes fixed and movable electrodes to hold and press a workpiece therebetween, and a sub pressure force applicator having a sub pressure unit that moves and selectively stops at a plurality of positions including a sub pressure position where the sub pressure unit is adjacent to the fixed electrode and in contact with the workpiece so as to apply a sub pressure, and a sub-pressure-non-requiring position where the sub pressure unit is located away from the workpiece. Spot welding is performed by applying current between the electrodes while holding the workpiece between the fixed electrode together with the sub pressure unit located in the sub pressure position and the movable electrode. Spot welding is also performed by applying current between the electrodes while holding the sub pressure unit in the sub-pressure-non-requiring position and holding the workpiece between the electrodes.

Abstract: A method for charging an intermediate-circuit capacitor for a welding device, includes feeding a voltage from a first chopping section of a first half-cycle of an AC voltage into the intermediate circuit capacitor, the first chopping section beginning at a first phase-related starting time; and feeding a voltage from a second chopping section of a second half-cycle of the AC voltage following the first half-cycle into the intermediate circuit capacitor, the second chopping section beginning at a second phase-related starting time, which is earlier than the first phase-related starting time.

Abstract: The invention provides a switching electrode which has a small variation in resistance value even when a large amount of current is repeatedly cut off and can carry a stable amount of current even when it is continuously used. In the invention, the switching electrode is used in a switch which includes a first switching electrode tip (21) and a second switching electrode tip (22), brings the first switching electrode tip (21) and the second switching electrode tip (22) into surface contact with each other to carry a current, and separates the first switching electrode tip (21) and the second switching electrode tip (22) to cut off the current. At least one of contact surfaces of the first switching electrode tip (21) and the second switching electrode tip (22) is a flat surface having an uneven portion.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A method for welding weldable parts together, for instance for welding annular objects (1), wherein the parts (IA, IB) are subjected to a thermal resistance upset welding process for making the parts (IA, IB) flow together at contact surfaces (S), wherein the welding process (W) depends on a number of input parameters, comprising a pressure exerted on the parts to be welded and a heating current fed through the parts (IA, IB), wherein a number of welding process output parameters, for instance a welding temperature and a displacement of the parts (IA, IB), depend on the input parameters, wherein, during the welding process (W), at least one welding temperature and/or electrical resistance of said parts (IA, IB) is determined, wherein the result of the welding temperature determination and/or resistance determination is used by at least one regulator (R) for automatically readjusting a number of welding process input parameters during the welding process (W), or for automatically adjusting the welding process

Abstract: An arc welding system and methods. The system is capable of monitoring variables during a welding process, according to wave shape states, and weighting the variables accordingly, detecting defects of a weld, diagnosing possible causes of the defects, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A simulator facilitating virtual welding activity. The simulator may include a logic processor based subsystem operable to generate an interactive welding environment in virtual reality space that emulates welding activity by simulating a virtual weld puddle having dynamic, real time molten metal fluidity and heat dissipation characteristics, responsive to performing a simulated welding activity in real time. The simulator may include a foot pedal device in operative communication with the logic processor based subsystem and configured to affect a characteristic of the virtual weld puddle in real time, responsive to user control of the foot pedal device. The simulator may be configured to track the movements of a mock welding tool and a mock filler wire and determine interaction between the virtual weld puddle, a corresponding virtual welding tool, and a corresponding filler wire in virtual reality space that would result in the welding tool becoming contaminated.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: A method to diagnose weld integrity in a welding process includes monitoring a weld indentation characteristic, comparing the monitored weld indentation characteristic to a threshold weld indentation characteristic, and identifying a discrepant weld when the weld indentation characteristic comparison shows the monitored weld indentation characteristic violates the threshold weld indentation characteristic.

Abstract: A sensing system measures the voltages between the electrodes of a resistance welding apparatus. The resistance welding apparatus has a pair of welding electrodes configured to come into electrical contact to effect a weld, a weld controller and a controller rectifier. The sensing system includes a voltmeter for measuring a voltage between the pair of electrodes and a sensor for sending a signal to initiate welding to the weld controller based on the measured voltage between the pair of welding electrodes. Related methods are also described.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: An arc welder including an integrated monitor is disclosed. The monitor is capable of monitoring variables during a welding process and weighting the variables accordingly, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A welding assembly including a current generator, an electrode electrically coupled to the current generator, the electrode including a first engagement surface, and a workpiece including at least two members, wherein at least one of the members includes a second engagement surface, defines a recess in the second engagement surface, and is electrically coupled to the current generator.