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: The invention relates to a device for identifying defects during the feeding of a welding rod. A sensor assembly (27) is located in the welding torch (10) for detecting the feed pressure and the feed tension for the welding rod (13), a drive device (31) for feeding the welding rod being located downstream of said sensor assembly (27) in the feed direction of the welding the direction of the arrow (30)).

Abstract: A system (10) for conducting welding adjacent flammable materials (12) on a platform (11) is disclosed having a chamber (13) defining an interior space (16). The system also includes a welding apparatus (48) operable within the interior space. A sensor (54) is provided for sensing the presence of combustible gas within the interior space above a pre-selected level and generating a signal. An exterior sensor (57) is provided for sensing the presence of combustible gas outside the interior space above a pre-selected level and generating a signal. A controller (66) is in communication with the welding apparatus, the sensor, and the exterior sensor to control the operations of the welding apparatus in response to signals received from the sensor.

Abstract: The present invention generally relates to a useful online monitoring system and method of user thereof for monitoring a welding process to determine weld quality, weld process stability, and weld geometry for each weld formed during a welding process. More particularly, the online monitoring system has a computer having a graphical user interface (GUI); at least one welding machine; a communication interface for interfacing communication between the at least one welding machine and the computer; a data acquisition system for acquiring welding signal data, the data acquisition system having an associated memory means; a quality management database for managing and storing acquired welding signal data; and a statistical signal processing system in communication with the data acquisition system for processing welding signal data stored in the data acquisition system associated memory means, and in further communication with the communication interface for communicating processed welding signal data to the GUI.

Abstract: The present invention generally relates to a useful online monitoring system and method of user thereof for monitoring a welding process to determine weld quality, weld process stability, and weld geometry for each weld formed during a welding process. More particularly, the online monitoring system has a computer having a graphical user interface (GUI); at least one welding machine; a communication interface for interfacing communication between the at least one welding machine and the computer; a data acquisition system for acquiring welding signal data, the data acquisition system having an associated memory means; a quality management database for managing and storing acquired welding signal data; and a statistical signal processing system in communication with the data acquisition system for processing welding signal data stored in the data acquisition system associated memory means, and in further communication with the communication interface for communicating processed welding signal data to the GUI.

Abstract: The invention describes a welding system with a welding device (1) and a protective device (28), in particular a protective shield (29) for a user or welder. The protective device (28) has an electrically controllable and/or adjustable protective visor (31) with a control system (32). The welding device (1) or the welding system consists of at least one current source (2), a welding torch (10) and a control unit. The protective device (28) has a transmitter and/or receiver unit (33) which is connected to the control system (32).

Abstract: An arc welding apparatus (10) for performing a waveform-controlled arc welding process includes an arc welding torch (14) that interacts with an associated weld. A power supply (12) applies a selected waveform-controlled power to the welding load via the arc welding torch (14) and a grounding cable over a process interval (Tweld). The power supply (12) includes a sampling circuit (34) for sampling instantaneous current and voltage values of the power during a snip portion (Tsnip) of the process interval (Tweld). A processor (40) is designed to (i) compute a true heat over the snip portion (Tsnip) of the process interval (Tweld), and (ii) extrapolate a true heat over the process interval (Tweld) based thereon.

Abstract: The invention describes a method of detecting welding process voltage, whereby the welding process voltage between a welding torch (10) and a workpiece (16) is detected and the welding process voltage is calculated in real time taking account of the interference variables of a welding system, in particular an inductance and a resistance.

Abstract: The invention relates to a device for metal welding, comprising a shielding element (1) which allows visual monitoring of the working process but protects the eyes from light radiation. The device comprises a video camera (5) which is directable towards the welding zone for recording the welding process in the form of video signals transmitted, via an image processing unit, to a video display unit (7), which the user is able to view and which is placed in or on the inside of the shielding element (1). The image processing unit reads process data from the video signals and presents the same via the video display unit.

Abstract: An arc welding quality evaluation apparatus for consumable electrode gas shielded arc welding comprises a heat input detection means 8 for detecting heat input applied to a workpiece to be welded; a welding time detection means 11 for detecting the welding time of the workpiece; a spatter weight detection means 16 for detecting the weight of spatter produced during the welding time of the workpiece; a heat compensation means 17 for compensating for heat loss due to spatter occurring during the welding time of the workpiece; an effective heat input computation means 12 for computing effective heat input per unit welding time, based on detected values of the detection means 8 and 11, and a compensation value of the heat compensation means 17; and a weld quality assessment means 22 for comparing an output of the effective heat input computation means 12 to a reference standard value, and assessing weld quality acceptability based on the degree of separation of the computation means output from the reference stan

Abstract: An apparatus and process for determining whether a fault has occurred in a welding process while the process is under way. The invention is applicable to welding and cutting processes where there is an arc plasma, such as gas-metal arc welding, tungsten-inert gas welding, pulsed welding, resistance welding and submerged welding. It involves sampling welding voltage and welding current to provide first and second signals, generating artificial third signals from these dependent on values of the first and second signals through generalised discrete point convolution operations, identifying corresponding values as triplets and collecting triplets of values into groups or regions.

Abstract: Systems and methods are disclosed for determining an impedance between a grounding device such as a welding wire feeder ground clamp and a power supply common, and selectively allowing current flow through an electrical device associated with a welding operation according to the impedance.

Abstract: A welding voltage is determined based on an expression, P=k2×Vw2+k3×Vw, where, with a welding wire feed speed and a welding wire radius used as inputs, a power factor is P(kW), the a melting speed of a welding wire is Vw(g/sec), and k2 and k3 are constants(k2=0.898 and k3=4.625).

Abstract: Welding voltage and welding current supplied to a workpiece from a welding wire 3 of a consumable electrode gas shielded arc welding apparatus are detected by a welding voltage detection means 11 and a welding current detection means 12. A replacement index for an electrode tip 5 is computed by a replacement index computation means 13, based on the average values of the welding voltage and welding current during arc time. A wear assessment means 14 assesses the state of wear of the electrode tip 5 by comparing the replacement index to a prescribed reference value. When the electrode tipreaches its prescribed wear limit (when its replacement index reaches the prescribed reference value), this fact is indicated by a replace tip indicator means 15.

Abstract: The present invention relates to an apparatus for assessing start-of-weld and steady state welding stability in pulsed arc consumable electrode gas-shielded welding. According to the present welding stability assessment apparatus, in order to obtain a pass/fail decision on start-of-weld welding stability for pulsed arc welding, an irregularity value is computed by a computer means, based on detected values from a detector means; and a pass/fail decision is made by an assessment means, thus making it possible to perform accurate assessment of start-of-weld welding stability in pulsed-arc welding.

Abstract: The present invention discloses a glare shielding device. The glare shielding device includes a microprocessor for controlling an activation time and a driving time of a liquid crystal panel. The microprocessor generates an activation control signal of a liquid crystal activating portion, a driving control signal of a liquid crystal driving portion, and a power off control signal in response to a simultaneous detection of a welding light and a high frequency generated during a welding process. The liquid crystal activating portion becomes a floating state in a standby mode and activates the liquid crystal panel using a minus voltage between a high voltage and an activation voltage. The liquid crystal driving portion becomes a floating state in a standby mode and drives the liquid crystal panel in response to the driving control signal.

Abstract: A method of determining the impedance, inductance, and resistance of the network connecting an electrical power supply to an electric arc welding station including an electrode and a workpiece, wherein the method comprises: shorting the electrode to the workpiece; creating at least one waveform including a first state operating the power supply at constant current of a selected value and a second state operating the power supply at a low value of current or open circuit voltage whereby the current decays from the selected value along a decay path indicative of di/dt; obtaining the average current Iavg and average resistance Ravg during the first state; selecting a portion of the decay path; sampling the instantaneous current for a number of times on the path during the second state to read the rate of the decay; and, using the average current and the average resistance with the rate of decay to obtain the inductance of the network.

Abstract: The present invention provides a weld monitoring system and method that monitors and automatically coordinates information on the quality of each weld in a workpiece having one or more welds. In particular, each weld in the workpiece is automatically analyzed at the time it is being made using weld sensors such as those that measure current, wire feed, voltage, and gas flow to produce information on the quality of the weld. Using this information, the welds are sorted, displayed, and logged with workpiece and weld number information which is provided to the operator in real-time and stored in a computer for access at a later time for quality control or other purposes. Therefore, the system and method enables welds of a quality less than a pre-determined quality for the weld to be identified in real-time and information concerning any particular weld to be accessed at a later time.

Abstract: A device for terminating operation of the power source of an electric arc welder for passing a current between an electrode and work piece from a first stud connected to the electrode by a first cable and a second stud connected to the work piece by a second cable to perform a welding process. The welder includes an output transformer with a known turns ratio, a primary winding and secondary winding. A first voltage sense lead is connected to the electrode and a second voltage sense lead connected to the work piece. The novel device comprises an executive program to implement a test sequence involving (a) a program routine for comparing a real time theoretical voltage, determined by the pulse waveform at a given time of the waveform, and the voltage at the sense leads at the given time; (b) a program routine to terminate operation of the power source when the theoretical voltage substantially exceeds the sense lead voltage; and, (c) a timing routine to perform the executive program at a set period.

Abstract: An arc welding apparatus (10) for performing a waveform-controlled arc welding process includes an arc welding torch (14) that interacts with an associated weld. A power supply (12) applies a selected waveform-controlled power to the welding load via the arc welding torch (14) and a grounding cable over a process interval (Tweld). The power supply (12) includes a sampling circuit (34) for sampling instantaneous current and voltage values of the power during a snip portion (Tsnip) of the process interval (Tweld). A processor (40) is designed to (i) compute a true heat over the snip portion (Tsnip) of the process interval (Tweld), and (ii) extrapolate a true heat over the process interval (Tweld) based thereon.

Abstract: An arc welding overlay apparatus that comprises a welding head carriage adapted for movement on a track, an index arm mounted for movement in a direction substantially transverse to the track, a slide mounted for movement in a direction substantially transverse to the index arm, a welding torch mounted to the slide, and means for dispensing a filler material to the welding torch. Feedback means and control means cooperate to indicate and control the movement of the weld head carriage, index arm, electric arc length and the filler dispensing rate. Means are also provided for emergency shutdown of the electric power source.

Abstract: An arc welding overlay apparatus that comprises a welding head carriage adapted for movement on a track, an index arm mounted for movement in a direction substantially transverse to the track, a slide mounted for movement in a direction substantially transverse to the index arm, a welding torch mounted to the slide, and means for dispensing a filler material to the welding torch. Feedback means and control means cooperate to indicate and control the movement of the weld head carriage, index arm, electric arc length and the filler dispensing rate. Means are also provided for emergency shutdown of the electric power source.

Abstract: An arc welding quality evaluation apparatus for consumable electrode gas shielded arc welding comprises a heat input detection means 8 for detecting heat input applied to a workpiece to be welded; a welding time detection means 11 for detecting the welding time of the workpiece; a spatter weight detection means 16 for detecting the weight of spatter produced during the welding time of the workpiece; a heat compensation means 17 for compensating for heat loss due to spatter occurring during the welding time of the workpiece; an effective heat input computation means 12 for computing effective heat input per unit welding time, based on detected values of the detection means 8 and 11, and a compensation value of the heat compensation means 17; and a weld quality assessment means 22 for comparing an output of the effective heat input computation means 12 to a reference standard value, and assessing weld quality acceptability based on the degree of separation of the computation means output from the reference stan

Abstract: Welding voltage and welding current supplied to a workpiece from a welding wire 3 of a consumable electrode gas shielded arc welding apparatus are detected by a welding voltage detection means 11 and a welding current detection means 12. A replacement index for an electrode tip 5 is computed by a replacement index computation means 13, based on the average values of the welding voltage and welding current during arc time. A wear assessment means 14 assesses the state of wear of the electrode tip 5 by comparing the replacement index to a prescribed reference value. When the electrode tipreaches its prescribed wear limit (when its replacement index reaches the prescribed reference value), this fact is indicated by a replace tip indicator means 15.

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 feeders 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: The present invention relates to an apparatus for assessing start-of-weld and steady state welding stability in pulsed arc consumable electrode gas-shielded welding. According to the present welding stability assessment apparatus, in order to obtain a pass/fail decision on start-of-weld welding stability for pulsed arc welding, an irregularity value is computed by a computer means, based on detected values from a detector means; and a pass/fail decision is made by an assessment means, thus making it possible to perform accurate assessment of start-of-weld welding stability in pulsed-arc welding.

Abstract: A welding machine having an embedded controller with a processor, a network gateway interface device coupled to the embedded controller, an operating program segment stored in a memory of the embedded controller, a gateway communication program segment stored at least partially in the memory of the embedded controller, and a resource sharing program segment stored in the memory of the embedded controller, the resource sharing program segment allocates processing time of the processor between the gateway communication program segment and the operating program segment. The machine may be monitored, controlled, accessed and updated with software over a network from a remote user interface, embodied for example on an Internet browser.

Abstract: A monitor for an electric arc welder as the welder performs a selected arc welding process by creating actual welding parameters, such as arc current and arc voltage, between an advancing welding wire and a workpiece, where the process involves an arc and is defined by a series of rapidly repeating wave shapes constituting a weld cycle with a cycle time, the wave shapes are each segmented into time states having command signals corresponding to the actual parameters and a time duration. The monitor selects a specific wave shape state, reads one of the actual parameters, compares the actual read parameter with a function of the command signal corresponding to the actual parameter, and uses-the comparison to generate a characteristic of the welding process during the selected state.

Abstract: A method of determining the impedance, inductance, and resistance of the network connecting an electrical power supply to an electric arc welding station including an electrode and a workpiece, wherein the method comprises: shorting the electrode to the workpiece; creating at least one waveform including a first state operating the power supply at constant current of a selected value and a second state operating the power supply at a low value of current or open circuit voltage whereby the current decays from the selected value along a decay path indicative of di/dt; obtaining the average current Iavg and average resistance Ravg during the first state; selecting a portion of the decay path; sampling the instantaneous current for a number of times on the path during the second state to read the rate of the decay; and, using the average current and the average resistance with the rate of decay to obtain the inductance of the network.

Abstract: The invention relates to a method and to a system for diagnosing and/or solving, in particular remotely, a given technical problem likely to arise before, during or after a heat treatment operation on metals, in particular in the welding or cutting field, and to provide the most suitable solution thereto, and to do so by minimizing the time needed to solve this problem and therefore by reducing the loss of productivity likely to occur because of this technical problem.

Abstract: A metal pipe inner surface weld-mounting apparatus having a monitoring device is constituted by an arm, a horizontal torch, a mirror, a camera and a monitoring device. The arm has a supported base end portion, which is horizontally extended. The horizontal torch is attached to a leading end portion of the arm. The weld-mounting is performed on an inner surface portion of a metal pipe supported rotatably around a horizontally extending axis while at least one of the metal pipe and the horizontal torch is moved in a direction of the axis. The mirror is attached to the leading end portion of the arm. The camera is disposed in a position separated from the mirror for picking up an image of weld-mounting beads in a neighborhood of arc light of the horizontal torch through the mirror. The monitoring device monitors a condition of the weld-mounting.

Abstract: A method for providing an analytical solution for a thermal history of a welding process having multiple weld passes. The method includes the steps of inputting a plurality of files and parameters, preprocessing information from the plurality of files and parameters to determine a set of conditions associated with the welding process, determining a region of influence of at least one heat source used in the welding process as a function of the set of conditions, determining a plurality of point heat source solutions within the region of influence, determining a temperature solution for each weld pass as a function of a superposition of the plurality of point heat source solutions, and determining the thermal history of the welding process as a function of the temperature solutions.

Abstract: The present invention provides an apparatus and method for achieving single-sided girth welds which adapt to and compensate for inherent geometrically induced difficulties in single-side girth welding applications. The inherent geometrically induced difficulties include those caused by axial misalignment, angular misalignment, and mismatched ovality. The present invention's apparatus and method minimize root defects due to undercut, incomplete penetration, excess penetration, or lack of fusion. The present invention provides accordingly limits defects introduced during the welding process and thus limiting fatigue failures. The present invention does not require the use of backing strips. The present invention further utilizes an improved lineup clamp for use in single-sided girth welding which does not cause damage to the interior of the pipes being welded.

Abstract: An apparatus for the concurrent inspection of partially completed welds is described in which is utilized in combination with a moveable welder for forming a partially completed weld, and an ultrasonic generator mounted on a moveable welder in which is reciprocally moveable along a path of travel which is laterally disposed relative to the partially completed weld.

Abstract: A method of determining the impedance, inductance, and resistance of the network connecting an electrical power supply to an electric arc welding station including an electrode and a workpiece, wherein the method-comprises: shorting the electrode to the workpiece; creating at least one waveform including a first state operating the power supply at constant current of a selected value and a second state operating the power supply at a low value of current or open circuit voltage whereby the current decays from the selected value along a decay path indicative of di/dt; obtaining the average current Iavg and average resistance Ravg during the first state; selecting a portion of the decay path; sampling the instantaneous current for a number of times on the path during the second state to read the rate of the decay; and, using the average current and the average resistance with the rate of decay to obtain the inductance of the network.

Abstract: Methods for weld monitoring and for laser heat treatment monitoring are provided using infrared emissions. In the method for weld monitoring, an infrared (IR) signature emitted by a hot weld surface during welding is detected. The detected infrared signature is compared with a steady state infrared signature signal. The compared results are correlated with a predetermined weld parameter. The predetermined weld parameter includes at least one of a full penetration weld, a workpiece misalignment, and a workpiece contamination. In the method for monitoring a laser heat treating process, an infrared (IR) energy signal emitted by a workpiece surface during the laser heat treating process is detected. The detected energy signal is compared with a predefined voltage range. The compared results are correlated to identify a potential defect.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal to drive the output current. The command signal is 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. Arc voltage 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 an instantaneous, or short-by-short, adjustment of the current command. A function of the time derivative of arc power, less the time derivative of arc current, is used to detect, in real time, when the short is about to clear. A stop algorithm is employed that monitors the arc on a short-by-short basis. When the process is ending a very low current level is provided to avoid forming a ball.

Abstract: A method for determining a heat source model for a weld. The method includes the steps of determining a double elliptical distribution of the heat density of the weld, modifying the double elliptical distribution as a function of a profile geometry of the weld, and determining the heat source model as a function of the modified double elliptical distribution.

Abstract: A process and a device are provided for determining the working voltage of welding current sources 25. The working voltage is determined partly outside the output terminals 23, 24 of the welding current source 25. The tap 2 is preferably performed on the wire electrode 16 or on the wire feed roller 17 of a wire electrode 16. The other tap 3, 4 may be performed on the workpiece 21, a workpiece connection 22 or on an output terminal 24 of the welding current source 25 or alternatively in the welding current source 25.

Abstract: This invention concerns weld quality measurement. In particular it concerns an apparatus and a process for measuring on-line, while the welding process is under way, the quality of the resulting weldment. The invention is applicable to spray-transfer gas-metal arc welding, short-circuiting transfer gas-metal arc welding, pulse welding, radio-frequency resistance welding and submerged arc welding. It involves the measurement of voltage or current and the generation of an artificial signal for the other. A two dimensional signal analysis then produces data for comparison with data obtained from a high quality weld.

Abstract: The invention provides an arc welding monitoring device by which it is possible to easily find how detected data such as a welding current and welding voltage correspond to trajectories of a robot, in other words, welding line information of a welding work. The arc welding monitoring device comprises means 4 and 5 for detecting at least either the welding current or welding voltage, a means 14 for storing the detected data, a means 14 for storing trajectories of a robot, and a means for displaying, on a screen display, at least either the welding current or welding voltage detected by said detecting means, and the trajectories of the robot stored by the storing means, wherein a range is determined on the trajectories displayed on the screen display, and arc welding monitoring display is enabled in compliance with the range.

Abstract: Apparatus for monitoring manual arc welding procedures for providing to the welder real-time monitoring of the welding characteristics to achieve optimum welds. The voltage and current conditions of the welding arc are instantly transferred within the visual range of the helmet wearing operator by the use of lights, illuminated bar graphs, light projections, illuminated see-through displays, or the like, located in proximity to the helmet viewing window wherein, through such monitoring, the operator is constantly aware of the arc conditions during welding.

Abstract: Apparatus for determining a quality of a weld produced by a welding device according to the present invention includes a sensor operatively associated with the welding device. The sensor is responsive to at least one welding process parameter during a welding process and produces a welding process parameter signal that relates to the at least one welding process parameter. A computer connected to the sensor is responsive to the welding process parameter signal produced by the sensor. A user interface operatively associated with the computer allows a user to select a desired welding process. The computer processes the welding process parameter signal produced by the sensor in accordance with one of a constant voltage algorithm, a short duration weld algorithm or a pulsed current analysis module depending on the desired welding process selected by the user. The computer produces output data indicative of the quality of the weld.

Abstract: A system for recording a welding situation and a welding state includes an acoustical input means 2, a welding state detecting means 3, and a data recording means 4. A situation information indicating a welding situation is input by voice of an operator by the acoustical input means 2, and a welding information indicating a welding state at that time is detected by the welding state detecting means 3. The acoustical information and the welding information are recorded as regeneratable date by the date recording means 4.

Abstract: A method and apparatus for monitoring quality of a weld bead during a welding process utilizing an electronic controller is disclosed. The method and apparatus includes determining an average power spectral density value for a first welding parameter signal between a first predetermined frequency and a second predetermined frequency, determining an average power spectral density value for a second welding parameter signal between a first predetermined frequency and a second predetermined frequency, and comparing the average power spectral density value for the second welding parameter signal with the average power spectral density value for the first welding parameter signal and terminating the welding process if the average power spectral density value for the first welding parameter signal exceeds the average power spectral density value for the second welding parameter signal.