Abstract: The present invention provides a system and a method for real time monitoring and identifying defects occurring in a three dimensional object build via an additive manufacturing process. Further, the present invention provides in-situ correction of such defects by a plurality of functional tool heads possessing freedom of motion in arbitrary planes and approach, where the functional tool heads are automatically and independently controlled based on a feedback analysis from the printing process, implementing analyzing techniques. Furthermore, the present invention provides a mechanism for analyzing defected data collected from detection devices and correcting tool path instructions and object model in-situ during construction of a 3D object. A build report is also generated that displays, in 3D space, the structural geometry and inherent properties of a final build object along with the features of corrected and uncorrected defects.

Abstract: Welding headwear comprises a display operable to present images for viewing by a wearer of the welding headwear, and comprises circuitry operable to determine an identifier associated with a workpiece, retrieve, from memory, welding work instructions associated with the identifier, and generate the images for presentation on the display based on said work instructions.

Abstract: A welding-type system includes a welding-type power supply to output welding-type power, and a controller connected to the welding-type power supply. The controller is configured to set a value of a control variable of a control loop of the welding-type power supply, the control loop controlling the welding-type power. The controller is also configured to adjust the value of the control variable while monitoring the control loop. In response to detecting oscillation in the control loop, the controller is configured to determine a weld circuit inductance associated with a weld circuit of the welding-type system based on a relationship between the adjusted control variable value and the weld circuit inductance.

Abstract: Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

Abstract: When setting welding conditions of arc welding, an operator sets the shape of a material to be welded, the specifications of welding, and welding conditions using a teach pendant. An apparatus for supporting setting of welding conditions in multi-pass welding of the present invention automatically calculates the state of the bead layering cross-section including at least one of the number of bead layers, the number of passes, and the layering direction, and the state of the bead layering cross-section including at least one of the number of bead layers, the number of passes, and the layering direction, obtained by the calculation is displayed on a display section.

Abstract: A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on a desired welding temperature. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform. The desired welding temperature is one of a temperature setpoint and a temperature range.

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: 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 system or an enterprise using welding systems can communicate with cloud-based resources for the provision of services and products to facilitate the welding operations. The communications may be via wired or wireless media, and may be direct, or through other components, such as enterprise networks, peripheral devices, and so forth. The cloud-based resources may provide for storage of data, particularly welding data, processing of data, welding protocols, specifications and processes, financial transactions for the purchase, licensing or use of welding-related products and services, welding training, and so forth.

Abstract: A method is disclosed for ascertaining a focus image distance of an optical sensor, which is provided with a lens, of a coordinate-measuring apparatus onto a workpiece to be measured, wherein the optical sensor and/or the workpiece are movable in a Z direction such that a distance in the Z direction between the workpiece and the optical sensor is variable. Further, a corresponding coordinate-measuring apparatus and a computer program product are disclosed.

Abstract: The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch, and a sensor, in which the sensor is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor. The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

Abstract: A welding system includes an electrode configured to be advanced toward a workpiece and a power supply configured to provide a flow of electricity to the electrode for generating a welding arc between the electrode and the workpiece. The welding system also includes a first sensor configured to sense a light intensity of the welding arc and a second sensor configured to sense a current provided to the electrode via the power supply. In addition, the welding system includes a controller communicatively coupled with the first and second sensors and configured to modify the light intensity with respect to the current. The controller is configured to control a welding parameter of the welding system based on the modified light intensity.

Abstract: An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece. Molten metal droplets are quickly created during negative polarity portions of the weld cycle. Welding controls include integrating a parameter during the negative polarity portions to determine when a desired amount of energy has been generated at the welding wire. This energy is associated with a desired droplet size for consistent droplet transfers to the workpiece.

Abstract: A robot controller configured to be able to mitigate the effect that an emergency stop may have on a robot is disclosed. The robot controller includes: a load detection unit which detects the load of a motor for driving each individual articulated axis of the robot; a speed detection unit which detects an axial speed at each individual articulated axis of the robot; a cause-of-stop identifying unit which, when an emergency stop of the robot occurs, identifies a cause of the occurrence of the emergency stop; and a recording unit which records the cause of the occurrence of the emergency stop by associating the cause with the axial speed or the load of the motor. The robot controller may further include a display unit which displays information representing the state of occurrence of the emergency stop of the robot.

Abstract: A welding facility inspecting apparatus may include a base apparatus that has a space in the interior thereof and surrounds the space in a horizontal direction, a first extension apparatus, a second extension apparatus, a first camera that is attached to the base apparatus, a second camera that is attached to the base apparatus at a same height as the first camera, a third camera that is attached to the first extension apparatus, a fourth camera that is attached to the second extension apparatus, and a measuring apparatus that is attached to the base apparatus in such a way that the measuring apparatus is disposed in the inner space of the base apparatus and that is configured to measure welding force and welding current of a welding gun.

Abstract: A welding-type system includes a helmet having a first image capture device configured to capture a first set of images of a work area from a first perspective and a second image capture device configured to capture a second set of images of the work area from a second perspective. The helmet also includes an electronic display configured to display the first and second sets of images substantially simultaneously to cause a stereoscopic appearance of the work area via the electronic display. Moreover, the helmet includes an audible command translation unit configured to receive audible commands configured to adjust operation of a power supply configured to supply power for the welding-type system. Furthermore, the welding-type system includes a processing system communicatively coupled to the audible command translation unit and configured to adjust at least one parameter of the power supply based at least in part on the received audible commands.

Abstract: Dynamic range enhancement methods and systems for display for use welding applications are described. A display system in a dynamic range enhancement system can include, for example, a splitter, a high density filter, a low density filter, a first image sensor, a second image sensor, a graphical circuit, and a display. The high density filter and the first image sensor can be disposed in a first path. The low density filter and the second image sensor can be disposed in a second path. The first image sensor can receive filtered electromagnetic waves from the high density filter. The second image sensor can receive filtered electromagnetic waves from the low density filter. The graphic circuit can combine the signals from the first image sensor and the second image sensor to provide a high dynamic range image or video that is displayed on the display of a welding helmet, for example.

Abstract: Provided herein is a welding diagnostic device, a method of identifying a metal transfer mode of a welding process presently being performed and a transfer mode identifier for use with a GMAW welding machine. In one embodiment, the welding diagnostic device includes: (1) a welding data interface configured to receive a welding voltage from a welding machine during a welding process and (2) a data acquisition system configured to, during the welding process, determine a metal transfer mode of the welding process based on the welding voltage and provide a sensory indication thereof.

Abstract: A method for monitoring a spatter generating event during a welding application. The method includes capturing data that corresponds to a welding current of the welding application. The method also includes detecting parameters associated with a short circuit from the captured data. The method includes analyzing the detected parameters to monitor the spatter generating event during the welding application.

Abstract: Embodiments described herein include wireless control of a welding power supply via portable electronic devices. In particular, operating parameters and statuses of the welding power supply may be modified by the portable electronic device, as well as be displayed on the portable electronic device. For example, in certain embodiments, the welding power supply may be an engine-driven welding power supply, and the portable electronic device may be configured to start and/or stop an engine of the engine-driven welding power supply. A pairing procedure may be used to pair the welding power supply and the portable electronic device in a wireless communication network. Furthermore, in certain embodiments, a method of prioritization of control between a control panel of the welding power supply and the portable electronic device may be implemented.

Abstract: A welding training system includes a camera configured to capture video data corresponding to a welding training operation. The welding training system also includes a storage device configured to store the video data, and to store welding parameter data corresponding to the welding training operation. The welding training system includes a welding training software configured to retrieve the video data from the storage device, to retrieve the welding parameter data from the storage device, to synchronize the video data with the welding parameter data, and to provide the synchronized video and welding parameter data to a display device.

Abstract: A method and apparatus for welding is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.

Abstract: A process application robot system in which a process condition can be adjusted even when operation limitation regarding setting the condition is valid, while ensuring safety regarding management and operation of the process condition. The robot system includes a robot which carries out a predetermined process operation; a robot controller which controls the robot; a process controller which controls a processing treatment in the process operation; an interface part for setting, changing or adjusting a process condition which determines a content of the process treatment; and a process condition change managing part which carries out an operation limitation with respect to setting of or setting change in the process condition. The content of the process condition which is set when the operation limitation is invalid is determined as a reference condition, and the process condition can be adjusted within an adjustable range based on the reference condition.

Abstract: A method and system for internally determining, within a welding power supply, the energy input into a weld during a welding operation. The method includes determining a total energy input into the weld during a first time period, and determining a length of the weld made during the first time period.

Abstract: A wire management method using a wire manager including current sensing features provides input for power measurement and management systems. The wire manager may be a single wire or single bundle retaining device with a current sensor such as a hall effect sensor integrated therein, or may be a multi-wire management housing with multiple current sensing devices disposed inside for measuring the current through multiple wires. The wires may be multiple branch circuits in a power distribution panel or raceway, and the wire manager may be adapted for mounting in such a panel or raceway. Voltage sensing may also be incorporated within the sensors by providing an electrically conductive plate, wire or other element that capacitively couples to the corresponding wire.

Abstract: The invention discloses a method to determine the weld joint penetration from arc voltage measurements in gas tungsten arc welding (GTAW). It is based on an observation on the dynamic weld pool surface in GTAW—the surface tends to first expand toward the electrode and then be pushed away from the electrode after full penetration is established. For the pool surface in GTAW, localized partial keyholes around the arc axis as in plasma arc welding are not significant. The pool surface is relatively smooth. The arc voltage that reflects changes in the arc length thus first tends to reduce and then increases after full penetration is established. This invention thus tracks the arc voltage until the decrease slope becomes insignificant. Once full penetration is established, the current is reduced to decrease the weld penetration or first decrease the penetration growth for a certain period and then decrease the weld penetration.

Abstract: Provided is a plasma arc welding method for continuously welding a welding target part of a welding workpiece while forming a keyhole weld on the welding target part of the welding workpiece using a plasma arc. A pulse current is used for a welding current, and the pulse frequency of the pulse current is controlled so as to be a frequency that is synchronized with a weld pool (P) during the welding. With this approach, vibration of the weld pool during keyhole welding can be controlled so as to synchronize with the pulse frequency of the pulse current. As a result, when the plasma arc keyhole welding is performed, a stable penetration bead having a desired height can be reliably obtained without hanging or irregularity.

Abstract: A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on one of a desired RMS voltage set point and a desired RMS voltage range. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform.

Abstract: The invention relates to a method and a device for optically measuring the interior of a seamless pipe which is manufactured by rolling or of a pipe which is welded with a longitudinal seam and is manufactured from sheet-metal plates shaped to form half-shells or from a shaped sheet-metal plate or from a metal strip which is unwound from a coil, comprising a sensor means (9) which emits a laser beam (10) in the interior of the pipe (3). In such a method and device, an internal measurement of seamless pipes or pipes which are welded with a longitudinal seam is to be provided with which it is easily possible to determine and model precisely the ovalness and straightness of the pipe (3) in a station.

Abstract: Various welding systems including a welding torch assembly are provided. The welding torch assemblies may include a welding torch adapted to be utilized in a welding operation to establish a welding arc between the welding torch and a workpiece. The welding torch assemblies may also include a temperature sensing system integral with the welding torch and adapted to sense a temperature of the workpiece.

Abstract: A method of monitoring and assessing contact tip useful life in a GMAW-pulse application. The pulse welding waveform includes current and voltage that periodically change between peaks and background. The welding current and voltage are measured on a series of repeated representative welds. The data that corresponds to the arc start and the arc stop of a weld is removed. The data is averaged for each representative weld, which corresponds to production of welded parts and/or usage of the contact tip. The deterioration of the contact tip is assessed based on one or more of (i) a decrease in the frequency of the peaks, (ii) an increase in the length of the background, and (iii) an increase in the occurrence of abnormal low voltage. The assessment is outputted as contact tip life data, and continuously fed to a controller or operator.

Abstract: A method of production of a welded joint which enables improvement of the fatigue strength in the case where measures for improvement of the fatigue strength cannot be applied due to the presence of structurally sealed regions is provided. The method is provided with a first weld step which performs welding by forming an inside weld toe or root part by using a weld metal with a transformation start temperature of 175° C. to 400° C. in range, at least parts of the weld metal forming the inside weld toe or root part which was formed at the first weld step becoming unmelted parts, and a second weld step which performs welding for building up the weld metal by a single pass by a weld heat input by which all of the unmelted parts are retransformed to austenite so as to introduce compressive residual stress to the inside weld toe or root part.

Abstract: A semi-automatic brazing apparatus having a brazing wire feeding apparatus containing a brazing wire feed mechanism, a controller, and a user input device. The brazing wire from a brazing wire source is continuously drawn from the source through the apparatus via the feeding mechanism and is directed towards a brazing gun for a semi-automatic brazing operation.

Abstract: A method to determine welding conditions includes relational expressions or tables about various parameters for setting welding conditions. The method can determine and display the recommended values for the welding conditions which are suitable for the information about the object to be welded and the information about the welding method set by the operator. The welding conditions include a welding current, a welding voltage, a wire feed speed, a welding speed, and a leg length. Furthermore, if the operator changes the recommended value for a welding condition to a new value, the method can determine new recommended values for the other welding conditions compatible with the new value and display the new recommended values.

Abstract: In consumable-electrode gas-shield arc welding, carbon dioxide gas is used as shield gas; the molten pool is formed using a pulsed arc as a leading electrode arc transferring one droplet per cycle by alternately outputting, in each cycle, pulses of two different pulse waveforms of which a pulse peak current level and/or a pulse width per period differ; the conductively heated filler wire is inserted into the molten pool as a trailing electrode; the distance between a tip of the filler wire inserted into the molten pool and a conductive point of the filler wire is set within a range of 200×10?3 to 500×10?3 m; and a leading-electrode base current value is set larger than a trailing-electrode filler current value. According to such a method, even when inexpensive carbon dioxide gas is used as shield gas, the amount of spatter can be reduced, and high weldability can be achieved in multipass welding.

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 contact welding detection system includes a main circuit including a DC power source, a power-supply unit electrically connected to the DC power source, and a main circuit relay electrically connected between the DC power source and the power-supply unit, a measurement unit measuring an electrical characteristic value on a signal wiring between a signal generation unit and the main circuit. The system further includes a welding determination unit configured to determine the presence or absence of contact welding in the relay on the basis of the electrical characteristic value, and a first forced ground-contacting unit electrically connected between the main circuit and a conductive member connected to ground. The first forced ground-contacting unit is electrically connected to the main circuit at a connection point located on an opposite side of the relay to a connection point at which the signal generation unit is electrically connected to the main circuit.

Abstract: The invention relates to a welding device (1), comprising a connection (27) for a welding torch (7) for performing a welding process, a power source (2) for supplying the welding torch (7) with a welding current, a control device (4) and an input/output device (18), formed by a touch screen (21) and connected to said control device (4), for setting/displaying parameters, functions and the like. In order to make the welding device (1) as easy to operate as possible and allow parameters to be changed quickly on the touch screen (21), the control device (4) is designed for the sequential and circumferential setting/display of parameters in a main area (28) of the touch screen (21), wherein the settable parameter is displayed emphasised in the centre of the main area (28).

Abstract: A system and method for controlling a hybrid welding process. An integrated hybrid welding power source includes a first power supply for providing a first welding output and a second power supply for providing a second welding output. The first power supply and the second power supply are operatively connected to coordinate the first welding output with the second welding output in real time while operating concurrently.

Abstract: One embodiment of the present invention relates to a system for buried-arc welding with thru-the-arc seam tracking. Another embodiment of the present invention relates to a method for buried-arc welding with thru-the-arc seam tracking.

Abstract: A system and method of rating the arc maintainability of an electric arc welding stick electrode by creating an arc between the electrode and a workpiece; moving the electrode along the workpiece while maintaining the arc; decreasing either the current or the voltage until a point is reached where the arc is extinguished; determining the open circuit voltage at the point; and, rating the electrode based upon at least the open circuit voltage point.

Abstract: A system and method for determining weld travel speed. In one example, a welding system includes one or more sensors configured to provide a first indication correspond to a welding arc at a first time and to provide a second indication correspond to the welding arc at a second time. The welding system also includes processing circuitry configured to receive the first indication, to receive the second indication, and to determine a weld travel speed based on a weld length of the workpiece and a difference between the first and second times.

Abstract: In a method for controlling pulse arc welding where an arc is created between a wire and a base material, a pulse waveform different from the pulse waveform for steady-state welding is outputted when a predetermined time has passed since short-circuit welding control was started at arc start, and after a sufficiently large melt pool is formed, the pulse waveform for the steady-state welding is outputted. This reduces the generation of spatters after an arc is created and until the arc is stabilized.

Abstract: Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

Abstract: A welding system includes a repositionable temperature sensor. The repositionable temperature sensor is configured to detect temperatures corresponding to a workpiece and to provide temperature data corresponding to the detected temperatures. The welding system also includes a power supply configured to receive the temperature data from the temperature sensor. The power supply is configured to modify control of an output of the power supply based on the detected temperature.

Abstract: A welding observation apparatus is provided to use partial darkening by a telecentric optical system and a photochromic filter (PCF) as an optical system for filtering light emission from arc discharge in order to verify the welding condition under the welding arc discharge, without forming an image on the PCF, so that light reducing performance can be secured even if a focus shifts from on the PCF, with satisfactory monitoring of welding condition. The welding observation apparatus comprises: an arc welding unit 8; an objective optical system (1, 2) for concentrating light from the arc welding unit 8; a telecentric optical system 3 for guiding the light concentrated by the objective optical system (1, 2); a PCF 4 for illuminating with the light guided by the telecentric optical system 3; and a solid state imaging device 9 for receiving the light passing through the PCF 4, wherein the light from the arc welding unit 8 is partial-darkened by the PCF 4.

Abstract: A robotic welding equipment station to detect deviation of a tool center point of a welding torch. The station is provided with pairs of light emitting and detecting devices to emit and detect two separate light beams. The pairs of light emitting devices and detectors are oriented at an angle and spaced apart from each other such that the two light beams are at an angle to one another and the weld wire electrode is able to simultaneously interrupt both light beams when there is no deviation in a tool center point. The spacing prevents the weld wire electrode from interrupting both light beams when an increasing deviation of the tool center point propagates along the length of the weld wire electrode. First and second output signals generated by the first and second light detectors are received by a means for detecting deviation of the tool center point.

Abstract: Provided herein is a welding diagnostic device, a method of identifying a metal transfer mode of a welding process presently being performed and a transfer mode identifier for use with a GMAW welding machine. In one embodiment, the welding diagnostic device includes: (1) a welding data interface configured to receive a welding voltage from a welding machine during a welding process and (2) a data acquisition system configured to, during the welding process, determine a metal transfer mode of the welding process based on the welding voltage and provide a sensory indication thereof.

Abstract: If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.

Abstract: A system and a method for tracking and analyzing welding activity. Dynamic spatial properties of a welding tool are sensed during a welding process producing a weld. The sensed dynamic spatial properties are tracked over time and the tracked dynamic spatial properties are captured as tracked data during the welding process. The tracked data is analyzed to determine performance characteristics of a welder performing the welding process and quality characteristics of a weld produced by the welding process. The performance characteristics and the quality characteristics may be subsequently reviewed.