Abstract: A robot controller that controls a tandem arc welding system according to the present invention includes a leading-electrode correcting section that calculates a leading-electrode correction amount, used for correcting a displacement in a left-right direction and an up-down direction, from a leading-electrode changing amount calculated by a leading-electrode processing section; a leading-electrode correcting section that calculates a trailed-electrode correction amount, used for correcting a displacement in a rotational direction, from a trailed-electrode changing amount calculated by a trailed-electrode processing section; a rotational-displacement correction controlling processing section that calculates a rotational-center correction amount for correcting the displacement of the leading electrode; and a robot trajectory planning processing section that corrects a teaching position and a position of a rotational center of a welding torch during tracking correction.

Abstract: A 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 the open circuit voltage point.

Abstract: A system and method for determining the approximate weight of metal consumables used by an electric arc welder over a period of welding time, the system comprises a program to calculate the total energy exerted by the welder over a period of welding, a divider to divide the total energy by a number including a power of a selected non-unity factor to obtain said weight. When the energy is in mega joules the factor is in the range of 3.2-4.2 and preferably approximately 4.0.

Abstract: Various embodiments of a method for monitoring a machine condition are provided. An embodiment of the present invention provides a method of monitoring a machine condition, comprising the following steps: modeling a normal signal model performed by detecting a signal for monitoring condition of a normal machine and converting the detected signal to a normal signal model in time domain using a hidden Markov model (HMM) algorithm; calculating a probability value data of the monitoring signal at a subject machine performed by detecting a signal for monitoring condition of the subject machine in real-time and converting the detected signal to the probability value data relative to the normal state signal model using the HMM algorithm; and determining a section having deficiency where the probability value data of the monitoring signal at the subject machinery is not maintained constantly relative to the normal signal model.

Abstract: Described herein is a system for monitoring arc-welding processes, comprising arc-voltage sensor means (21) and arc-current sensor means (22), means (23) for acquisition of voltage values (V) measured by said arc-voltage sensor means (21) and of current values (I) measured by said arc-current sensor means (22), and processing means (25) configured for processing said voltage values (V) and said current values (I) for calculating one or more vectors of time values (Ton[j]; TonV[j), TonI[j]) corresponding to a state of arc of the arc-welding process, According to the invention, said processing means (25) are configured for executing the operations of: calculating reference values (TssupV, TsinfV, TssupI, TsinfI) of arc time (Ton[j]; TonV[j), TonI[j]) via the steps of: calculating a statistical distribution of respective arc-time vectors (Ton[j]; TonV[j), TonI[j]) obtained from voltage values (V) and from current values (I), measured during execution of one or more reference welds; and calculating as referen

Abstract: A monitoring apparatus is configured for association with a welding machine. The welding machine is configured to receive welding wire from a wire source. The monitoring apparatus includes a power input port, an indicator, and a detector, each of which is supported by a housing. The detector is in electrical communication with each of the power input port and the indicator. At least one of the housing and the detector at least partially defines a zone configured to removably receive a longitudinal portion of a welding wire passing from the wire source to the welding machine. The detector is configured to facilitate passage of electrical current from the power input port to the indicator depending upon whether iron material is disposed within the zone. Methods are also provided.

Abstract: A quality assurance system includes an internet/wide area network interface configured to provide bidirectional communication with user terminals; a wireless interface configured to provide bidirectional communication with mobile user terminals; and a quality assurance database cooperatively coupled with a database manager. The data base manager is configured to populate the quality assurance database with identifications of individual ones of a plurality of construction project welders, weld inspectors and a plurality of weld data logs individual ones of which are associated with a specific welding operation of a construction project. Each weld data log is configured to store information that is at least descriptive of a welder, material used during the specific welding operation, specifics of a completed weld including at least weld location, weld type and weld dimensions, and information descriptive of a weld examination.

Abstract: A welding torch includes: a contact tip having, on a distal-end inner circumferential surface thereof, a power supply portion that contacts a fed welding wire to supply current; and a wire guide that is provided having a predetermined clearance within the contact tip and guides the fed welding wire, and wherein the arc-welding torch is configured such that axes of the contact tip and the wire guide are relatively changed so as to cause the welding wire fed while guided by the wire guide to contact the power supply portion of the contact tip. The power supply portion of the contact tip is formed to have an axial length with which a welding current can be maintained at at least a predetermined lower limit current despite a shift of a power supply point in accordance with wear of the power supply portion, more specifically, formed to have a length of 1 to 4 mm.

Abstract: Plasma cutter and welder units are provided for fabricating a pipe. The plasma cutter and welder unit include a support structure having a carriage rotatably supported thereon. A plasma cutter nozzle and a weld nozzle are mounted to the carriage. A drive mechanism adjusts positioning of the plasma cutter and weld nozzles through varying control by a controller during operation. Additionally, a bearing support is provided for cradling the pipe during fabrication. The bearing support includes a plurality of bearing plates. A wedge structure is secured to each of the bearing plates and to a fixture base to form a nest for receiving the pipe. An isolation pad is disposed between the wedge structure and the fixture base.

Abstract: A system that facilitates dynamic configuration of a welding system with respect to a sensor comprises a processing unit associated with the welding system. A configuration component facilitates configuring the welding system with respect to the sensor upon determining that the sensor is coupled to a local bus associated with the processing unit. A remote access component can facilitate remotely accessing the welding system, the configuration of the welding system alterable by way of the remote access component.

Abstract: A method for quality control of a weld bead made using a welding tool. The method collects, by an optical pyrometer having a high frequency acquisition sensor, at least one signal representative of the temperature of a melted portion of the weld bead, and includes a frequency phase for checking that the recurring frequencies are within an acceptable range of reference frequencies, to determine if the weld bead is defective.

Abstract: Warning and shutdown systems and methods are presented for providing advance warnings of pending fault conditions to an operator of an arc processing system. The warning system comprises an input, a logic system, and a signaling system, where the input receives a sensor signal indicative of an operational condition of the arc processing system, the logic system detects a pending fault condition based on the sensor signal, and the signaling system provides a warning signal to the operator, wherein the warning signal is indicative of the pending fault condition. Shutdown apparatus is provided which has a sensor input, a logic system to detect a fault condition, and a shutdown system that selectively shuts the arc processing system down a predetermined time period after fault detection.

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: An apparatus for splicing optical waveguides has a memory circuit in which data items which identify a state of the apparatus for splicing the optical waveguides are stored. The memory circuit is used to store data items which identify a state of the optical waveguides to be spliced. Stored data items indicate conditions of the environment in which a splice process has been carried out. The apparatus can be used to record a plurality of data items which can be evaluated for analysis of a splice process, in particular for an analysis of a fault which has occurred during the splice process.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to a true energy and/or true power input to the welding output circuit path. A welding output circuit path is also characterized with respect to an inductance of the welding output circuit path. A welding output circuit path is further characterized with respect to a welding output waveform.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to at least one of a true energy and true power input to the welding output circuit path.

Abstract: A welding-type apparatus and method providing controlled termination of a welding-type process includes monitoring an arc parameter and setting a threshold based on the monitored arc parameter. When the arc parameter achieves the threshold, weld power is gradually reduced until arc termination. The system provides for a controlled arc termination process which is dynamically defined by the characteristics of each welding arc.

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

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command to drive the output current. Feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by adjustment of the current command. The short being about to clear is detected in real time. When the process is ending a very low current level is provided to avoid forming a ball. If a short is created, after the low current level, a burst of energy is provided to clear of burn off the short. After the short is cleared, very low current is again provided to avoid forming a large ball, until the wire stops and the process ends.

Abstract: A method controls a welding apparatus by using a neural network to recognize an acceptable weld signature. The neural network recognizes a pattern presented by the instantaneous weld signature, and modifies the instantaneous weld signature when the pattern is not acceptable. The method measures a welding voltage, current, and wire feed speed (WFS), and trains the neural network using the instantaneous weld signature when the instantaneous weld signature is different from each of the different training weld signatures. A welding apparatus for controlling a welding process includes a welding gun, a power supply for supplying a welding voltage and current, and a sensor for detecting values of a plurality of different welding process variables. A controller of the apparatus has a neural network for receiving the welding process variables and for recognizing a pattern in the weld signature. The controller modifies the weld signature when the pattern is not recognized.

Abstract: A method monitors a weld signature of a welding apparatus by processing the signature through a neural network to recognize a pattern, and by classifying the weld signature in response to the pattern. The method determines if the weld signature is sufficiently different from training weld signatures stored in a database, and records the weld signature in the database when sufficiently different. The method tests a weld joint to determine values of different weld joint properties, and then correlates the signature with the weld data to validate the database. An apparatus monitors a weld signature during a welding process to predict welding joint quality, and includes a welding gun, a power supply, and a sensor for detecting welding voltage, current, and wire feed speed (WFS). A neural network receives the welding process values and classifies the signature into different weld classifications each corresponding to a predicted welding joint quality.

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 welding system including an arc monitoring, training, and control system is disclosed. The welding system includes a power supply, controller, and associated memory. When a weld is performed, the weld command and weld feedback parameters can be stored in the memory, along with associated alarm limit values. During subsequent welds, the input weld commands and actual feedback values can be compared to the established limits, and a fault signal provided to an operator or supervisor when the value exceeds the established limits. The fault signals can be used for training operators, as well as providing monitoring signals, and can be stored with weld data in a database for later analysis. In addition, collected weld data can be used to determine when to clean, repair, or replace consumables, including, for example, contact tips, wire drive liners, and drive rolls, and to monitor usage of wire and gas.

Abstract: A robot welding apparatus including a welding station having a welding robot with weld tips for creating a weld along a work piece. A welding power supply and control pendant is also provided. A visual screen of the control pendant provides a view of the weld tips for use with the method to detect characteristics such as weld tip face measurement, tip wear measurement, tip alignment measurement, and cap replacement and type verification.

Abstract: An apparatus for bonding a conductive lead to a conductive terminal of a device by the use of a conductive metal ball is disclosed and claimed. A ball-forming wire comprises a first conductive metal having a first melting temperature. A clamping surface has a closed position in contact with the ball-forming wire. A wire-clamping actuator is coupled to the clamping surface and is electrically connected to a clamping signal source. A sparking pin comprises a second conductive metal having a second melting temperature higher than the first melting temperature. The sparking pin is electrically connected to a power source. A current detection transformer includes a magnetic core at least partially encircling the ball-forming wire. An analyzing circuit is electrically connected to the current detection transformer.

Abstract: A discharge voltage detecting unit 7 detects a discharge voltage and determines an average discharge voltage in a specified period of time. An optimum machining condition computing unit 8 determines a discharge current that makes an average discharge voltage detected by the discharge voltage detecting unit equal to an average discharge voltage when a new machining liquid is used and determines discharging time, non-operating time, and a servo reference voltage depending on the determined discharge current from the relational equations with a discharge current, discharging time, non-operating time, and a servo reference voltage that are stored in the machining condition data base storing unit 9 and establish optimum machining conditions and controls a servo 4 and a machining electrode 5 under the optimum machining conditions by a servo control unit 6 at the time of machining.

Abstract: A method and apparatus of comparing two or more welding flux systems to determine which flux system results in the smallest incidence of undercut about a weld bead in an inner diameter of a pipe.

Abstract: The present invention relates to a system and method that provide for automated notification to entities (e.g., individuals, groups of individuals, computers, systems . . . ) of welding system related information. The invention provides for determination of events and/or conditions that warrant automatic notification thereof to relevant entities. The notifications are conveyed via a most appropriate subset of available communication modes available. The system identifies most appropriate entities to receive the notification about the event, and optionally determines or infers state of the entities and conveys the notification via a communication mode (e.g., text, audio, graphical, video, combination thereof . . . ) and modality (e.g., wireless, Ethernet, cable, optical, telephone, e-mail, voicemail, pager, ghosting, instant messaging . . . ) that is most suitable given context/state of the event and entities.

Abstract: Systems and methods are presented for tactile communication with an operator in an arc processing system, in which a tactile device is mechanically coupled with a handheld torch to provide tactile messages to the operator according to information related to the system or to an arc processing operation being performed.

Abstract: The invention provides an arc welding robot capable of collecting and displaying waveform data in a welding operation without using an external device. The arc welding robot comprises: a manipulator 101 including a welding torch 124 mounted thereon; a control unit 102 for operating the manipulator 101 in a given operation pattern in accordance with a previously taught operation program, the control unit 102 including therein a welding control part 104 for welding a member to be welded 125 under a given welding condition, and a RAM 106 for recording waveform data relating to at least one of a welding current instruction value, a welding current output value, a welding voltage instruction value, a welding voltage output value, a welding speed, a wire feed speed, the number of times of short circuits and a wire feed motor current during a given period; and, display means for graphically displaying the waveform data recorded in the RAM 106.

Abstract: A system and method for determining the approximate weight of metal consumables used by an electric arc welder over a period of welding time, the system comprises a program to calculate the total energy exerted by the welder over a period of welding, a divider to divide the total energy by a number including a power of a selected non-unity factor to obtain said weight. When the energy is in mega joules the factor is in the range of 3.2-4.2 and preferably approximately 4.0.

Abstract: A method of measuring the quality of a stick electrode used in forming the root bead of a pipe joint, which electrode has a wire diameter, a length substantially greater than 12 inches and an upper exposed rod head. The method comprises: preparing a standardized workpiece including two spaced plates with a groove between the plates having a set profile including a lower gap duplicating the root gap of the pipe joint and mounting the standardized workpiece on an incline with the groove facing upwardly where the incline is at a fixed known angle. Then a stick electrode of the type to be measured is selected and the rod head of the selected electrode is connected to the power lead of a DC power source set to a given output current correlated with the type of electrode.

Abstract: A method and apparatus of comparing two or more welding flux systems to determine which flux system results in the smallest incidence of undercut about a weld bead in an inner diameter of a pipe.

Abstract: Stick welding electrode rating and ranking procedures are provided for determining stackability performance of stick electrodes for pipe welding operations. The rating technique involves performance of a standardized vertical down weld procedure using a stick electrode to form a weld bead in a test workpiece groove, in which the electrode is maintained during welding at a substantially constant angle relative to the workpiece groove. The electrode is advanced toward the groove at a slow speed to deposit molten metal in the groove while keeping the molten metal above the stick electrode end or the arc thereof without dripping. The resulting bead distance is measured along with the welding time and the stick electrode is rated according to a ratio of the weld time and the bead distance.

Abstract: A workpiece movement sensing system can be used with an automated stud welding machine and/or process. The system includes a sensor measuring applied voltage relative to lift height utilized during the stud welding process. A workpiece movement detection module detects workpiece movement occurring during one or more welds. Upon detection, an operator can be notified, and/or automatic voltage compensation can be turned on.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to a true energy and/or true power input to the welding output circuit path. A welding output circuit path is also characterized with respect to an inductance of the welding output circuit path. A welding output circuit path is further characterized with respect to a welding output waveform.

Abstract: The invention relates to a method for setting a parameter for external control units (30) of a welding device (1), whereby the welding parameters can be selected and set using different control elements (27) and indicating elements (28) on the welding device (1). The aim of the invention is to provide a method of this type with which a flexible adaptation of setting options of external components (29) connected to the welding device (1) is made possible for the most varied applications or welding processes. To this end, a control program (32) is activated in the welding device (1), whereby the selected welding parameter for setting or adjusting is selectively assigned to an external control unit (30) located on an external component (29) so that this welding parameter is set or changed when the external control units (30) on the external components (29) are activated or adjusted.

Abstract: A number of methods to support process quality and maintenance during control of an industrial process such as welding are provided. The methods provide, among other things: automatic process limit programming based on runtime data; user-initiated process limit programming based on upcoming data; correlate equipment deterioration based on capability measurement; correlate tip dressers/formers to new; detect electrical deterioration; integrate process data with programmed data for a visual aid; and quantify process variation in welding tools (pareto of stddev of the c-factor).

Abstract: An electrode position detection system for a welder having a laser that is projected in a lateral plane to laterally cross a welding wire at a location below a contact tip of a welding gun and a receiver that receive the laser bean after crossing the welding wire, and a measuring device that determines one or more parameter of the welding wire based on the received laser beam. Arc voltage measurements can also be used to determine one or more parameter of the welding wire.

Abstract: A multifunction meter and method for monitoring a welding-type device is disclosed. The multifunction meter has a single display unit, a first input configured to receive feedback from an engine, and a second input configured to receive feedback from a power converter. The engine is configured to deliver power to the power converter which is configured to deliver a welding-type power to a welding-type apparatus. A processing unit is connected to the single display unit, the first input, and the second input, and processes the feedback from the engine and the feedback from the power converter and displays data indicative of engine operation and power output of the power converter on the single display unit.

Abstract: Methods of controlling an arc welding shop. In the shop, several welding torches are used and each torch is supplied with consumable wire. The wire moves at a wire speed and is subjected to an electrical current. For each torch, either an average wire speed or an average electrical current, as measured over a fixed time period, is determined by a sensor. These values then allow productivity parameters to be selected for the torches. Productivity parameters include the duty factor, the deposition rate, the average duty factor, and the average deposition rate.

Abstract: It is an object to provide an arc welding apparatus capable of causing an operator to easily decide a welding abnormality and the quality of a welding condition by simultaneously displaying a welding current command value, a welding voltage command value and a wire feeding speed command value and switching and displaying an actual welding current value, an actual welding voltage value and an actual wire feeding speed. There are provided a welding torch (8), a wire feeding device for feeding a wire (9) in contact with the internal surface of a chip (17) of the welding torch (8), a welding source (4) for supplying a power to the chip (17) and a base metal (13), a welding current detector (30) and a welding voltage detector (31), and a wire feeding speed command value, a welding current value and a welding voltage value are displayed independently and simultaneously.

Abstract: Methods and systems are disclosed for characterizing a welding consumable, such as flux or an electrode, and/or for comparing two or more welding consumables for use in narrow gap deep groove welding operations, including creating test welds on fixtures having joint grooves of various angles for a given groove depth, followed by controlled standardized non-aggressive slag removal operations, and quantification of the amount of slag remaining in the groove, wherein the welding consumables are each characterized using the same fixtures, welding conditions, workpiece groove depths, groove angles, and removal operations, to construct a set of results, such as a table or rating, by which the individual welding consumables can be rated and/or a determination can be made as to which of two consumables provides superior performance with respect to ease of removal in deep groove welding operations.

Abstract: A method and apparatus can adaptively control a pulsed power arc welding process. A trainable system can recognize an empirical transfer mode from a signal emitted during an arc welding pulse and determine a pulsed power parameter set to produce a modified transfer mode in a subsequent pulse, by controlling a power source using the parameter set.

Abstract: A process and a system are proposed for short-time arc welding, in particular for stud welding, with the step of sampling a welding parameter, in particular the arc voltage (U), during at least one time segment (Ts) of the welding operation, in order to detect disturbances, wherein the measurement curve determined from the sampling operation is smoothed and subsequently wherein at least one tolerance curve is generated which lies at a previously adjustable distance from the smoothed measurement curve, and subsequently the unsmoothed measurement curve is compared with the tolerance curve in order to detect high-frequency disturbances.

Abstract: An electrode position detection system for a welder having a laser that is projected in a lateral plane to laterally cross a welding wire at a location below a contact tip of a welding gun and a receiver that receive the laser bean after crossing the welding wire, and a measuring device that determines one or more parameter of the welding wire based on the received laser beam. Arc voltage measurements can also be used to determine one or more parameter of the welding wire.

Abstract: A tandem welding system includes a plurality of spaced apart electrodes (12, 14, 16, 18) arranged to travel at a common travel speed. The plurality of spaced apart electrodes (12, 14, 16, 18) cooperatively perform a weld. A data storage medium (74) stores measured data for each electrode during the performing of the weld. A processor (110) performs a process comprising: for each electrode, recalling measured data corresponding to the electrode passing a reference position; and, combining the recalled measured data of the plurality of spaced apart electrodes (12, 14, 16, 18) to compute a weld parameter of the tandem welding system at the reference position.

Abstract: A method and apparatus for providing welding-type power are disclosed. They include a source of welding-type power and at least one welding system peripheral. Each includes a network module that has boot loader software. A network is connected to the two network modules, and the network has connection for updates that is capable of receiving software updates. The network connection for updating may be on a user interface module, disposed inside or outside of a housing of the source of welding-type power and may include an RS232 connection. The network modules may include application software. The peripheral may be a wire feeder, a robot interface, or any other peripheral. A second peripheral, with a network module and boot loader software, may also be connected to the network. The updating can occur when the system is powered up. The software update is obtained from a personal computer, a personal digital assistant, or over the internet.

Abstract: Proposed is a device for welding metal elements, in particular studs, to structural parts, having a welding head that has a collet chuck for the accommodation of an element, having a feed unit for the feed of elements into the chuck, and having a power supply means for the supply of electric energy for a welding procedure. The chuck has at least two segments electrically insolated from one another. It can be detected via an applied test voltage whether a metal element to be welded is located in the chuck.

Abstract: A welding and network information system and methodology is provided in accordance with the present invention.