Abstract: Methods and systems for creating and controlling an AC output for welding, plasma cutting or heating are provided. One embodiment of the present disclosure achieves a desired square wave AC output and reduces the number of circuit components needed by combining components of a buck converter and a full bridge inverter. Current flow paths through a power control circuit that are generated via switching of transistors in the circuit on and off are provided. In one embodiment, a pulse width modulation leg, which controls the level of current flow through an inductor, is provided. Certain embodiments include a bidirectional buck converter that converts an unregulated DC flow to a regulated DC flow through an inductor. In one embodiment, a steering leg is provided, which controls a direction of current flow through the inductor. Additionally, an output clamp circuit, which suppresses the parasitic load inductance during polarity reversal is provided.

Abstract: A system and device operating using a welding power bus are provided. One welding power supply includes control circuitry configured to control the operation of the welding power supply and power conversion circuitry configured to convert input power to output welding power. The welding power supply also includes welding terminals configured to receive the output welding power from the power conversion circuitry and to provide the output welding power to a device that does not use the welding power for a welding operation. The control circuitry is configured to adapt the output welding power to the device.

Abstract: A welding current source for supplying an electric welding current circuit with electric current and electric voltage for carrying out an electric welding process, wherein the welding current source is provided with a power conditioning device for conditioning electric current supplied to the welding current source for suitability in an electric welding process, wherein furthermore on a housing of the welding current source there are provided two pole contact devices, each of which protrude from the housing, and the welding current source is equipped with a cooling device, with which thermal heat loss released by the welding current source can be dissipated. In the case of such a welding current source and despite sufficient cooling of the electrical components, it shall be possible that the housing of the welding current source can be designed to be also smaller than before.

Abstract: An apparatus to provide welding power. The apparatus may include a direct current-alternate current (DC-AC) power converter to output a primary current and a transformer stage. The transformer stage may include at least one power transformer to receive the primary current from the (DC-AC) power converter on a primary side of the transformer stage and to output a first voltage through a first rectifier and a first set of secondary windings disposed on a secondary side of the transformer stage. The transformer stage may further include an auxiliary set of secondary windings disposed on the secondary side to output a second voltage. The apparatus may also include a pair of active unidirectional switches disposed on the secondary side to receive the second voltage from the auxiliary set of secondary windings.

Abstract: Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

Abstract: A welding current source for providing a welding current and a welding voltage at an output in order to carry out an arc welding process includes an input-side rectifier, an inverter, which is operated with a switching frequency, a transformer having a primary winding and at least two secondary windings, at least two rectifiers arranged between the secondary windings and the output, and at least one capacitor and one load resistor at the output. At least one current-limiting reactor is arranged on the second secondary winding and the load resistor for discharging the capacitor, which can be charged by the current-limiting reactor, the current-limiting reactor, and the capacitor are dimensioned in such a way that the maximum value of the no-load voltage at the output is greater than the voltage corresponding to the transmission ratio of the primary winding to the secondary winding of the transformer.

Abstract: A silver-copper cutting electrode assembly, and method of manufacture is provided with optimized attributes to allow for improved durability, integrity and manufacturability. An electrode has a silver tip portion which is brazed to a copper body portion where the silver portion and joint have a particular structural relationship.

Abstract: A DC power supply device includes a housing including a wall portion, a first opening and a second opening, a circuit portion, a regulation wall portion, and a fan. The first and second openings are formed in the wall portion. The circuit portion includes first and second circuit elements those fixed within the housing. The regulation wall portion provide a first air passage in communication with the first opening, a second air passage in communication with the second opening, and a bent air passage allowing the first air passage and the second air passage to communicate with each other. The fan is configured to generate an air-flow flowing between the first air passage and the second air passage. The fan is positioned to face the first opening. The first circuit element is positioned in the first air passage. The second circuit element is positioned in the second air passage.

Abstract: A system and device operating using a welding power bus are provided. One welding power supply includes control circuitry configured to control the operation of the welding power supply and power conversion circuitry configured to convert input power to output welding power. The welding power supply also includes welding terminals configured to receive the output welding power from the power conversion circuitry and to provide the output welding power to a device that does not use the welding power for a welding operation. The control circuitry is configured to adapt the output welding power to the device.

Abstract: Embodiments of energy storage caddies adapted to couple to a welding power supply are provided. The energy storage caddies may include an energy storage device, a charger, control circuitry, and power conversion circuitry. Certain control circuitry may be adapted to control the energy storage device to discharge to provide a direct current (DC) voltage output to the welding power supply when a weld load demand is detected, to monitor a charge level of the energy storage device, and to alert a user to an error when the charge level of the energy storage device falls below a predetermined limit.

Abstract: To provide a compact welding torch in which a motor can be easily replaced, in which, when a motor capable of high-speed welding is used for a long time in a high current region, heat generated by the motor can be sufficiently cooled, and in which the motor can be protected from spatters or the like. A first cooler that cools a first side surface of a motor parallel to a shaft of the motor and a second cooler that cools a second side surface of the motor different from the first side surface are included. The first cooler has a first inflow port and a first outflow port for a cooling fluid, and a first flow passage that connects the first inflow port and the first outflow port. The second cooler has a second inflow port and a second outflow port for the cooling fluid, and a second flow passage that connects the second inflow port and the second outflow port.

Abstract: A system and device operating using a welding power bus are provided. One welding power supply includes control circuitry configured to control the operation of the welding power supply and power conversion circuitry configured to convert input power to output welding power. The welding power supply also includes welding terminals configured to receive the output welding power from the power conversion circuitry and to provide the output welding power to a device that does not use the welding power for a welding operation. The control circuitry is configured to adapt the output welding power to the device.

Abstract: A multi-process welding machine provides an intuitive user interface to enable a user to select among different welding processes, and to select parameters for a given selected welding process. The multi-process welding machine also provides an arrangement by which a switching module, or DC to AC converter, of an AC TIG unit can be controlled to alternatively supply AC or DC welding voltages or current. Further, a configuration of switches can be leveraged to automatically (or manually) control the polarity of welding cables for different processes and to engage or disengage a wire feeder when, e.g., a MIG welding process is selected, or not selected, respectively. Finally, in an embodiment, the ferrite or magnetic materials used for a main output inductor and an high frequency starting inductor of the welding machine can be combined.

Abstract: Systems and methods are disclosed relating to welding-type power supplies. In some examples, the power supplies may have no vents, which may help prevent environmental contaminants from entering the power supplies. Instead, the power supplies include one or more thermal interfaces configured to conduct heat generated by internal circuitry of the power supply from the interior of the power supply to an exterior of the power supply. Additionally, the thermal interface(s) may be configured for attachment to one or more exterior heat dissipating devices.

Abstract: The present disclosure discloses a voltage regulating apparatus, including a pre-stage circuit and a post-stage circuit. The pre-stage circuit receives an input voltage and outputs an intermediate bus voltage, and the post-stage circuit receives the intermediate bus voltage and outputs an output voltage. The post-stage circuit includes a plurality of post-stage converters, the post-stage converters are connected in parallel in an interleaved manner. In this way, the post-stage circuit has a small inductance, thereby reducing the volume of the apparatus and increasing the power density of the apparatus.

Abstract: A connector and sensor unit for a welding apparatus, including a first port configured to be connected to a first welding cable of the welding apparatus, a second port configured to be connected to a second welding cable of the welding apparatus, current sensor circuitry configured to sense a current being supplied by the first welding cable and the second welding cable, and to output a corresponding current sense signal, voltage sensing circuitry configured to sense a voltage between the first welding cable and the second welding cable, and to output a corresponding voltage sense signal, and supply power circuitry configured to generate a predetermined voltage for at least the current sensor circuitry, wherein the supply power circuitry receives power from the first welding cable and the second welding cable via at least one inductor.

Abstract: A power supply structure comprises a housing, a socket and a fan. The housing has a main housing, a terminal housing and a front panel, wherein the terminal housing connected with the main housing. The fan and the terminal housing disposed on one end of the main housing, and the fan attached to the front panel. The socket arranged in parallel with the fan and connected to the terminal housing.

Abstract: A method and apparatus for providing welding type power is disclosed. A welding type power supply includes an input circuit, a controller and an output circuit. The input circuit receives an input power signal and provides an intermediate power signal. The output circuit receives the intermediate power signal and provides a welding type power output. The output circuit has an inverter with at least two inverter switches, and a clamp circuit that limits the voltage across the inverter. The clamp circuit captures and buffers the excess energy, and returns the excess energy to an input of the inverter over a plurality of switching cycles. The controller has control outputs connected to the input circuit and the output circuit, to control them.

Abstract: A welding-type power system that provides balanced split phase AC power or three phase AC power from a DC power bus that includes a power supply, a DC power bus, inverters, and a balancing circuit. The inverters and the balancing circuit are configured in a half-bridge topology. The balancing circuit is configured to balance a neutral midpoint of the DC power bus. The balanced split phase AC power or three phase AC power is accomplished by actively controlling the neutral midpoint of the DC power bus via the balancing circuit.

Abstract: A method and apparatus for providing welding-type power includes an input circuit, a power circuit, and a controller. The input circuit receives input power and provides intermediate power. The power circuit has a power control input with at least one switch that responds to the control input. The power circuit receives the intermediate power and provides welding type output power. The controller has a set point input and a control output. The control output is connected to the power control input. The control circuit also includes a pwm module that responds to the user set point input and provided the control output. The pwm module can include a short duty cycle linearizing module. The pwm module can also include a short duty cycle charging ramp module.

Abstract: The invention is related to a method of initiating a regenerative converter (1) and corresponding converter (1) including a line bridge (2) and a machine bridge (3), which are interconnected via a DC intermediate circuit (8A, 8B). The method comprises charging, through the line bridge (2) and while the machine bridge (3) remains inactive, the DC intermediate circuit (8A, 8B) to a target voltage (14) higher than peak value of the mains voltage (13).

Abstract: A wind tunnel for a welding-type power supply has a primary section and a secondary section that combine to produce a primary cooling chamber and a secondary cooling chamber. Baffling on the primary and secondary sections define primary and secondary airflow paths through the primary and secondary cooling chambers. Fans may be configured to drive air along the airflow paths, and electrical components situated in the cooling chambers may be cooled by air flowing along the airflow paths. A divider comprising engaged partitions of the primary section and secondary section may separate and/or isolate the primary cooling path from the secondary cooling path. The wind tunnel may comprise an insulating material to provide electrical isolation (creepage and clearance) between electrical components.

Abstract: A method and apparatus for providing welding type power is disclosed. The output is cyclical, and is a controlled voltage output during the background and/or peak and a controlled current output during the transition up and/or down. During the controlled current portion the output is responsive to output voltage.

Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding torch. The power is provided in accordance with an electrode negative pulse welding regime that includes a cyclic peak, followed by a stabilization phase, then a return to a background level. The stabilization phase has a generally parabolic current shape, and is performed in a current-closed loop manner until a transition point, where control becomes voltage-closed loop until the background level is reached. Resulting weld performance is improved, with a globular-like transfer mode, reduced shorts and enhanced arc stability.

Abstract: The present disclosure provides a welding system having a welder, a welding gun, and a welding gun adapter, the welding gun being a spool gun with an attached motor. The welding gun adapter receives welding power from the welder, and converts it to output power suitable for driving the motor of the welding gun. The welding gun adapter also uses received welding power from the welder for control power. The present techniques allow for the use of welding guns requiring motor power to be used with any ordinary welder.

Abstract: The present invention is directed to a system and method of remotely controlling a welding machine with command signals transmitted to the welding power source across a weld cable connecting the power source to a remote device, such a wire feeder. A transmitter transmits the control commands containing desired welding operational parameters to a receiver disposed in the power source across a weld cable also designed to carry welding power from the power source to the wire feeder.

Abstract: A welding machine includes an enclosure and a welding power supply mounted in an electronics compartment within the enclosure. A divider wall at least partially defines an engine compartment. A generator is operatively connected to the power supply. An engine, located within the engine compartment, drives the generator. An engine-cooling fan is coupled to the engine. A recessed side vent is in fluid communication with the electronics compartment and recessed in a lateral side of the enclosure, and a recessed air channel is formed by the lateral side and extends rearward from the side vent along the engine compartment. The engine-cooling fan draws cooling air forward through the recessed side vent and into the electronics compartment, and downward through the electronics compartment and into the engine compartment.

Abstract: A battery powered welding system is provided. In one welding system a battery powered welder includes control circuitry configured to control a welding power output converted from power from an external battery power source. The battery powered welder also includes a wire drive assembly coupled to the control circuitry and configured to feed a welding wire using power from the external battery power source. The battery powered welder includes a case integrally supporting and enclosing the control circuitry and the wire drive assembly. The case is not configured to enclose the external battery power source.

Abstract: Provided is a welding robot mechanism that has: a welding robot having a touch sensing function; a welding power source for supplying welding power to the welding robot; and a control unit for controlling the welding robot, wherein the welding power source has a welding power source communication unit that receives detection signals with regard to control of the welding robot and the touch sensing, and transmits the detection signals outward. The control unit is linked to the welding power source communication unit via a serial bus communication wire. The detection signals comprise a mass of data including a detection data group designated as a first group and a detection data group designated as a second group, and is configured to read the detection data group designated as the first group in a shorter cycle than that for the detection data group designated as the second group. The detection data group designated as the first group includes a detection signal obtained by the touch sensing.

Abstract: In embodiments, a welding apparatus includes an automated wire feed mechanism to output wire at a wire feed rate, where the wire is to provide a welding arc to a weld site. The wire feed rate is based at least in part on selected power to be provided to the weld site. Additional embodiments are described and claimed.

Abstract: A method and apparatus for providing welding-type power includes receiving an input that may be either a single or a three phase input voltage. Three power modules, each having a single phase boost power circuit, and an output circuit process the input power. A weld output circuit receives and combines the outputs of the three power modules. An input power distribution module connects the three power modules such that each receives a unique single phase power signal. A controller controls the three power modules and the input power distribution module.

Abstract: In some aspects, power supplies for liquid cooled plasma cutting systems configured to support plasma arc generation by a torch head connected to the power supply can include: a set of electrical components for plasma arc generation; and a power supply housing containing the set of electrical components, the power supply housing having a front panel and at least two side panels and defining: a set of inlets for allowing a cooling gas to enter the power supply housing to thermally regulate the set of electrical components, at least one inlet of the set of inlets being positioned at a corner of the housing and oriented at a non-zero angle relative to the front panel and to at least one of the two side panels; and a set of vents for allowing at least a portion of the cooling gas to exit the power supply housing.

Abstract: Induction heating power supplies, data collection systems, and induction heating systems to communicate over an induction heating cable are disclosed. An example induction heating power supply includes a power conversion circuit configured to: convert input power into induction heating power and transmit the induction heating power via an induction heating cable, and at least one of a receiver circuit coupled to the induction heating cable and configured to receive data via the induction heating cable or a transmitter circuit coupled to the induction heating cable and configured to transmit data via the induction heating cable.

Abstract: Methods and systems for creating and controlling an AC output for welding, plasma cutting or heating are provided. One embodiment of the present disclosure achieves a desired square wave AC output and reduces the number of circuit components needed by combining components of a buck converter and a full bridge inverter. Current flow paths through a power control circuit that are generated via switching of transistors in the circuit on and off are provided. In one embodiment, a pulse width modulation leg, which controls the level of current flow through an inductor, is provided. Certain embodiments include a bidirectional buck converter that converts an unregulated DC flow to a regulated DC flow through an inductor. In one embodiment, a steering leg is provided, which controls a direction of current flow through the inductor. Additionally, an output clamp circuit, which suppresses the parasitic load inductance during polarity reversal is provided.

Abstract: A power converter may comprise a magnetic core, a transformer primary winding configured to generate a magnetic field in the magnetic core, and a transformer secondary winding matrix. The transformer secondary winding matrix may comprise a plurality of secondary windings configurable between various electrical connections relative to one another (e.g., in series or in parallel) to adjust a voltage conversion ratio of the power converter.

Abstract: Through the present invention, the load of a torch (16) applied to a welding workpiece (W) in a touch start method is reduced, and stability is significantly enhanced. A welding head (10) has a rigid straight-advancing movable part (12), an elevator drive tower (14) for moving the straight-advancing movable part (12) straight forward in the vertical direction, and a torch (16) mounted on the straight-advancing movable part (12) so as to be able to move in the vertical direction. One end part of a balance arm (28) rotatably attached to a multi-purpose support part (22) of the straight-advancing movable part (12) is connected to a torch body (30), and a balance weight (98) is attached to the other end part of the balance arm (28).

Abstract: A method and system to manufacture workpieces employing a high intensity energy source that irradiates a surface of a workpiece to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets. Preferably, a wire feeding device feeds the wire to the puddle, and a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire which is deposited into the puddle.

Abstract: A method and apparatus for providing welding type power is disclosed. At least one circuit board is used that is partially potted using a potting barrier affixed to the circuit board. The partially potted portion can be inside an enclosed air flow space.

Abstract: Hybrid welding modules are disclosed. An example hybrid welding module includes a welding input switch, an energy storage input switch, an energy storage output switching circuit, and a control circuit. The welding input switch receives welding-type input power and selectively outputs the welding-type input power to a weld circuit as first welding-type output power. The energy storage input switch receives the welding-type input power and selectively conducts the welding-type input power to an energy storage device. The energy storage output switching circuit converts energy output by the energy storage device to second welding-type power and outputs the second welding-type power to the weld circuit.

Abstract: An electric arc generation device includes an internal combustion engine operatively coupled to a generator, an arc generation power supply powered by the generator, an ECU configured to control a maximum power output level of the engine according to one of a low power routine and a high power routine, and a position signal receiver operatively connected to the ECU. The position signal receiver is configured to receive a position signal, generate current position information based on the position signal, and provide the current position information to the ECU. The ECU is configured to compare the current position information to predetermined region data, and automatically switch from one of the high power routine and the low power routine to a different one of the high power routine and the low power routine based on a result of the comparing, to automatically control the maximum power output level of the engine.

Abstract: An automated plasma cutting system is provided that includes a positioning system mounted to a support, an automated plasma arc torch mounted to the positioning system, and at least one power supply operatively connected to the automated plasma arc torch. The power supply may provide electrical power and fluid flow to the automated plasma arc torch for operation. The system further includes a controller in communication with the automated plasma arc torch and the power supply, and an auxiliary plasma arc torch operatively connected to the power supply, wherein the power supply provides electrical power and fluid flow to both the automated plasma arc torch and the auxiliary plasma arc torch. The automated plasma arc torch may process the workpiece to generate a set of features, while the auxiliary plasma arc torch may process/cut a residual framework of the workpiece remaining after formation of the set of features.

Abstract: A hybrid welding system is provided. In one embodiment, the welding system includes an engine-driven generator, an energy storage device, a contactor, and a controller. The controller may be configured to control delivery of weld power from the generator when a commanded output is below a threshold level, and from both the generator and the energy storage when the commanded output is above the threshold level. Closing of the contactor enables the energy storage device to contribute to weld power during welding operations and to be charged by the generator output independent of charging between weld operations. Additional hybrid welding systems and methods are also disclosed.

Abstract: In embodiments, a welding apparatus includes an automated wire feed mechanism to output wire at a wire feed rate, where the wire is to provide a welding arc to a weld site. The wire feed rate is based at least in part on selected power to be provided to the weld site. Additional embodiments are described and claimed.

Abstract: Welding-type systems and user interfaces having a color display for displaying physical setup instructions are disclosed. Example interface devices include a process selection input device, a display device, a memory, and a processor. The memory stores weld connection setup graphics and physical welding connections. Each of the plurality of weld connection setup graphics is a graphic of a perspective view of a power supply. The processor, in response to identifying a selected welding process type via the welding process selection input device, displays one of the plurality of the weld connection setup graphics via the display device. The processor detects a physical welding connection made at the power supply, determines, based on the detected physical welding connection, that the detected physical welding connection is incorrect for the selected welding process type, and displays an alert on the display device to indicate an error in the detected physical welding connection.

Abstract: Embodiments of the present invention are engine drive welding and/or cutting systems which optimize the utilization of engine drive systems, including hybrid engine drive systems. Embodiments include modular systems which allow for the remote utilization of a battery powered module which can be separated from an engine drive generator power supply. Other embodiments include engine drive power supplies that can communicate with a load coupled to the power supply, such as welders, cutters and wire feeders to determine an optimum operational level. Further embodiments include engine drive power supplies that can be coupled together to optimize fuel and system usage.

Abstract: An AC/DC conversion circuit, including: four bidirectional switches forming an H bridge; a capacitor connected between input nodes of the bridge; a capacitor connected between output nodes of the bridge; and a control circuit capable of controlling the bridge alternately to a first configuration where first and second diagonals of the bridge are respectively conductive and non-conductive, and to a second configuration where the first and second diagonals are respectively non-conductive and conductive, the control circuit being capable, during a phase of transition between the first and second configurations, of: turning off the switches of the first diagonal; and for each switch of the second diagonal, turning on the switch only when the voltage thereacross takes a zero value.

Abstract: A method and apparatus for providing a welding type power is disclosed. It includes an outer housing having a wind tunnel within the outer housing. Air flows through the wind tunnel in an air flow direction. The width of the tunnel is less at one location than at another location. Electrical components receive power and provide a welding type output. A first group of those components require air flow for cooling, and are disposed at least partially in the wind tunnel. A second group of components are not disposed in the wind tunnel. The wind tunnel can also change direction.

Abstract: Systems and methods to convert welding power to auxiliary power are disclosed. An example power conversion system includes: power conversion circuitry configured to convert an input voltage from a welding power supply unit to a second output to power an auxiliary load, the power conversion circuitry comprising: an input power converter configured to receive the input voltage from the welding power supply unit; an input-to-output isolation circuit configured to maintain the auxiliary load at a different potential than the welding power supply unit; and an output power converter configured to output power having a target frequency and a target waveform to the auxiliary load; and a processor configured to control the output of the power conversion circuitry based on feedback associated with power requirements at the auxiliary load.

Abstract: A linear light-emitting diode (LED)-based tube (LLT) lamp comprises a pulse amplitude control module, a power sustaining device, an LED driving circuit, and LED arrays. The pulse amplitude control module is configured to generate one or more voltage pulses in each alternate-current (AC) cycle in response to a half-wave direct-current (DC) voltage when the LLT lamp starts to receive power from an input AC line voltage and when the half-wave DC voltage drops to a few tens of volts in each AC cycle. The power sustaining device receives the one or more voltage pulses and builds up a DC voltage depending on pulse amplitudes. When an electric shock occurs, the DC voltage built up is not high enough to operate the LED driving circuit and thus to disable the LED arrays, without electric shock current leaking into an electrical conductor of the LLT lamp during relamping or maintenance.

Abstract: The present invention belongs to the technical field of argon arc welding machine, and particularly refers to a welding power supply and an AC-DC argon arc welding machine.