Abstract: In an integrated magnetic component for a switched mode power converter, comprising two magnetic cores forming an 8-shaped core structure and at least two first electric winding wires, wherein at least one magnetic core is an E-core, at least one of the first electric winding wires is wound on a flange of the E-core.

Abstract: A welding system performs communication accurately without provision of a control line between a welding power supply device and a wire feeding device. The welding system includes a welding power supply device, a wire feeding device, a welding torch, and power cables for supplying welding power from the welding power supply device to the welding torch. The system also includes power transfer lines for supplying power for driving a feeding motor disposed in the wire feeding device, so that the welding power supply device and the wire feeding device perform communication via the power transfer lines. The power transfer lines have less superimposed noise compared to the power cables. Accordingly, communication can be performed more accurately than in the case of performing communication via the power cables.

Abstract: Power transmission system (1) for power transmission of electric power (P) from a power source (2A) to a power sink (4A) which is connected to the power source (2A) via a power transfer cable (3), wherein the power source (2A) has a first pole with a first electric potential, which is connected via parallel current lines of a first conducting pair of the power transfer cable (3) to a first pole of the power sink (4A), and a second pole with a second electric potential, which is connected via further parallel current lines of a second conducting pair of the power transfer cable (3) to a second pole of the power sink (4A), wherein, during the power transmission via the current lines, a user data signal can be transmitted between the power source (2A) and the power sink (4A) via at least one conducting pair with current lines of the same electric potential, uninfluenced by the power transmission.

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 includes detecting whether a wire feeder is in communication with a welding power supply. The method also includes detecting a current welding process of the welding power supply if the wire feeder is in communication with the welding power supply. The method includes determining, at the wire feeder, a welding output polarity. The method also includes setting a new welding process based on the current welding process and the welding output polarity without a user selecting the new welding process.

Abstract: A voltage regulator device is disclosed, comprising a first pin and a second pin, a regulator circuit implemented between the first pin and the second pin, one or more internal blocks configured to be powered through a supply node to facilitate operation of the regulator circuit and an internal supply circuit coupled to the first pin, the second pin, and the supply node, the internal supply circuit configured to provide a supply voltage to the supply node from either or both of the first and second pins.

Abstract: A method and apparatus for monitoring weld cell and related activity is disclosed. The activity is sensed using a variety of sensors, and reported to the controller, or to a remote location.

Abstract: A method includes converting power by a power converter comprising a plurality of converter cells, and selectively operating at least one converter cell of the plurality of converter cells in one of an active and an inactive mode based on a level of a power reference signal.

Abstract: A power source for an electric arc welding process, wherein the power source comprises an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and an output in the form of a second DC output signal electrically isolated from the first DC output signal and with a magnitude of a given ratio to the first DC output signal; and, a third stage to convert the second DC output signal to a welding output for the welding process.

Abstract: An electric arc welding system for depositing weld metal along a groove between two edges of a metal workpiece where the system contains a first power supply and a second power supply, each providing a welding waveform to respective welding electrodes. The positive output terminals of both power supplies are coupled to the same contact tip and the negative output terminal of one of the power supplies is not coupled to the workpiece.

Abstract: A method includes converting power by a power converter comprising a plurality of converter cells, and selectively operating at least one converter cell of the plurality of converter cells in one of an active and an inactive mode based on a level of a power reference signal.

Abstract: Embodiments of the present invention are wire feeders and wire feeder cable connections which include a power block portion, a cable connection portion and a liner guide assembly portion. The liner guide assembly portion and power block portion are structured and assembly so that a liner guide can be removed from a welding cable from inside the wire feeder, without removing the cable connector from the wire feeder.

Abstract: A power supply for welding, cutting and similar operations includes a dual two-switch forward converter. The converter has two inverter circuits coupled in parallel but controlled to provide output power in an interleaved fashion. To avoid “walking” of the circuits (which could result in different duty cycles and imbalance of the load sharing), control signals are determined and applied to a first of the inverter circuits, and “on” times of the first circuit is monitored, such as by augmenting a counter to determine the number of clock cycles the first circuit is “on”. The same duration is then used for commanding output from the second inverter circuit. The duty cycles of both circuits is thus ensured to be the same regardless of changes in the total output power.

Abstract: Described is a circuit for converting electric power between a three-phase grid and a single-phase grid. The circuit includes, in at least one embodiment, a first transformer that is connected to the three-phase grid, a number of first converter stages assigned to the first transformer, the associated DC intermediate circuits and the associated second converter stages. The second converter stages are connected to each other at the alternating-current side outputs with the aid of a series connection.

Abstract: A method and apparatus for line-cycle storage of a single-phase cycloconverter. The method includes receiving input power from an input port of the singe-phase cycloconverter and monitoring an AC output port of the single-phase cycloconverter. The method measures energy stored in a line-cycle energy storage circuit coupled to one line of the AC output port of the single-phase cycloconverter, and determines a phase difference between a monitored AC voltage of the AC output port and the measured voltage of the line-cycle energy storage circuit. The method controls switches in the single-phase cycloconverter to selectively store energy in the line-cycle energy storage circuit based on the phase difference.

Abstract: A system includes a power supply, a first cable assembly, and a second cable assembly. The power supply includes a housing and supports extending from an upper portion of the housing. The first cable assembly has a clamp disposed at a distal end of a first cable extending from the power supply. The clamp is configured to be removably coupled with a workpiece. The second cable assembly has a torch disposed at a distal end of a second cable extending from the power supply. The housing includes one or more sloped panels configured to hold the first and second cables in a position wrapped about the upper portion of the housing when the clamp and the torch are coupled to the supports.

Abstract: An apparatus includes a coil assembly, a core, and at least one cooling channel. The coil assembly includes at least one winding configured to receive a varying electrical current. The core includes multiple segments, and the at least one winding is wound around portions of the segments and is configured to generate a magnetic flux. The at least one cooling channel is configured to transport coolant through the coil assembly or core in order to cool the coil assembly or core. Portions of the segments of the core can be separated from one another to form multiple cooling channels through the core, and the multiple cooling channels can be configured to transport coolant through the core. The coil assembly may include at least one insulative spacer having multiple cooling channels, and the multiple cooling channels may be configured to transport coolant through the coil assembly.

Abstract: Gas metal arc welding (GMAW) is a widely used process for joining metals. Its main advantage over its competition gas tungsten arc welding (GTAW) is its high productivity in depositing metals. However, to melt metal from the wire to deposit into the work-piece, additional heat is consumed and applied to the work-piece with an uncontrolled fixed proportion to the effective heat that melts the wire. Such additional heat is often in excess of the needed heat input for the work-piece. The side-effects include a waste of the energy, an increased distortion, and possible materials property degradation. This invention is to device a method to transfer this part of heat to melt the wire by adding two wires, which form a pair of arc spots, under a tungsten arc. It also devices a method to assure the arc between the two wires be maintained stable such that the transfer be successfully continuous.

Abstract: A DC power source to supply DC power to a plasma generator is configured as a simple and small-sized device that forms high voltage for generating a plasma discharge. A step of passing a short-circuit current for extremely short time through the voltage source step-down chopper provided in the DC power source and accumulating energy in a reactor is performed repeatedly more than once, so as to discharge the energy accumulated in the reactor to the output capacitance and raise the output voltage sequentially, thereby boosting the voltage up to the ignition set voltage. The short-circuit current is formed by a switching element of a boosting circuit provided in the DC power source. Boosting the voltage at the output terminal by accumulating and discharging the short-circuit current is repeated to raise the voltage at the output terminal of the DC power source up to the ignition set voltage.

Abstract: An arc welding apparatus includes a lifting motor. A speed adjustment circuit controls the lifting motor such that the rising speed of the welder decreases if a current of the welding power source is smaller than a set value, or increases if the value of the current is larger than the set value. A voltage adjustment circuit controls the welding power source such that the voltage increases if the number of times that the voltage falls below a determination voltage is larger than a set number of times or if periods for which the voltage remains below the determination voltage are longer than a set time, or decreases if the number of times that the voltage falls below a determination voltage is smaller than a set number of times or if periods for which the voltage remains below the determination voltage is shorter than a set time.

Abstract: A power supply includes power modules. Each of the power modules includes an input stage configured to convert an input voltage into an intermediate voltage, and an output stage configured to output a DC supply voltage according to the intermediate voltage. Input terminals of the input stages in the plurality of power modules are electrically connected in series, and the input stages are configured to be controlled with at least one first common control signal having a common duty cycle. Output terminals of the output stages in the plurality of power modules are electrically connected in parallel, and the output stages are configured to be controlled with at least one second common control signal having a common duty cycle. A method of supplying power is also disclosed herein.

Abstract: The object of the invention is a battery-operated welding and/or cutting device including a frame and at least one battery cell. The frame includes a cooling profile having an outer surface, which is in direct contact with the air surrounding the device. The cooling profile is provided to accommodate at least one battery cell, such that the cooling profile at least partly surrounds the battery cell in order to conduct heat from the battery cell to the cooling profile and, via the outer surface of the cooling profile, away from the device. The object of the invention is also a cooling profile.

Abstract: A dual power pin connector assembly for connecting both a MIG welding gun and a spoolgun to a welding machine. The dual power pin connector is comprised of a busbar portion that electrically and mechanically couples the positive output terminal of the welding machine power supply to a wire drive for the MIG welding gun. The connector is further comprised of an integral quick release assembly/clamping portion that electrically and mechanically connects the positive power supply terminal to a power supply cable for the spoolgun. The clamping portion receives and retains a power pin coupled to one end of the spoolgun power cable in a receptacle that is manually tightened and loosened.

Abstract: A portable IGBT (Insulated Gate Bipolar Transistor) of high reliability, compact size, and low cost includes a main circuit to which a control circuit and an auxiliary power supply circuit are connected. The main circuit includes, in sequence, an input rectifier filter circuit, an inverter circuit, a high-frequency primary transformer, and a secondary output rectifier circuit. The control circuit includes a PWM regulation circuit, an IGBT driving circuit, a current feedback circuit, and a current setup circuit. The inverter circuit includes a full-bridge hard switching structure, which has IGBTs constituting bridge arms that are sequentially conducted, so that their alternating conduction converts direct current into high frequency square wave alternating current, which flows through the high-frequency primary transformer and is then subjected to rectification to supply an output of low voltage direct current.

Abstract: Disclosed herein is a capacitive discharge welder that comprises a series of super capacitors (or ultra-capacitors) used as a power source. The capacitive discharge welder disclosed herein also comprises a dual function circuit that serves as an emergency stop circuit that is capable of redirecting or disconnecting the weld path in certain applications and situations and a drain circuit to drain a filter capacitor. The capacitive discharge welder disclosed herein is configured to use the super capacitor power supply in a direct discharge configuration as a CD welder. Additionally, the super capacitors are switched at frequency through a filter capacitor to produce a shaped DC welding waveform suitable for a wide variety of welding applications.

Abstract: A method for controlling a power source is specified. The power source comprises a first converter (1) for converting an input voltage (UE) to an intermediate circuit voltage (UZK, UZK1), an intermediate circuit capacitor (2) and a second converter (3) for converting the intermediate circuit voltage (UZK, UZK1) to an output voltage (UA). A process is being controlled at the output of the second converter (3). A digital process controller predetermines at least one parameter and/or the value thereof to control the intermediate circuit voltage (UZK, UZK1) for the first converter (1) depending on an event at the output.

Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

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

Abstract: 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: An electric arc welder for creating a welding process in the form of a succession of AC waveforms between a particular type of cored electrode, with a sheath and core, and a workpiece by a power source comprising a high frequency switching device for creating the individual waveforms in the succession of waveforms, each waveform having a profile is formed by the magnitude of each of a large number of short current pulses generated at a frequency of at least 18 kHz where the profile is determined by the input signal to a wave shaper controlling the short current pulses; a circuit to create a profile signal indicative of the particular type of electrode; and a select circuit to select the input signal based upon the profile signal whereby the wave shaper causes the power source to create a specific waveform profile for the particular type of cored electrode.

Abstract: A hybrid welder having a cabinet, an energy storage device supported by the cabinet and means for removably attaching the cabinet to the welder.

Abstract: A method of identifying and selecting welding electrodes and welding output parameters on a welding power source is provided. The method includes identifying electrodes and/or electrode packaging with distinct colors or patterns which correspond to properties of the electrode. The method also may include employing distinguishable identifying markings on a power supply which correspond to the electrodes to be used to allow for easy setting of output parameters.

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

Abstract: A method and a welding device for performing a welding process on a workpiece by a welding torch, uses a melting welding wire, which is arranged on a wire coil and may be supplied to the welding torch via a hose package, wherein different welding wires and different welding parameters are used depending on the geometry of the workpiece. A welding wire formed by the different interconnected welding wires in lengths depending on the geometry of the workpiece is arranged on the wire coil, so the welding process may be performed without interruptions using the different welding wires and the different welding parameters by supplying to the welding torch the welding wire formed by the different interconnected welding wires from the wire coil.

Abstract: An electric arc welder for creating an arc welding process between an electrode and a workpiece where the welder comprises a preregulator having a first DC signal as an input and a regulated second DC signal as an output, an unregulated isolation inverter to convert the regulated second DC signal into a DC power signal and a weld control stage for converting the DC power signal into a welding signal. A controller causes the weld control stage to conform the welding signal into a waveform to provide welding process between the electrode and the workpiece, which controller has an output control signal regulated to produce a selected waveform or waveforms and the polarity of the waveform or waveforms. A device selects one of several stored welding processes as a program and a corresponding polarity for outputting by the controller.

Abstract: A welding torch with a welding electrode and a welding electrode holder is provided. One welding torch includes a securing mechanism and an insulated grip. The securing mechanism is configured to secure an exposed central portion of a welding rod bounded by flux covered first and second sides. The securing mechanism is also configured to make electrical contact with the central portion of the rod for arc welding with the first side. The insulated grip is configured to cover the second side of the welding rod.

Abstract: A system, in one embodiment, may include a portable welder having a welding output, a charging output, a welding circuit coupled to the welding output; and a charging circuit coupled to the charging output. The charging circuit may be configured to automatically adjust power to the charging output based on a feedback associated with charging a battery.

Abstract: In a welding power supply, a feedback circuit senses electrical signals from the power output studs and from remote welding sense leads. The feedback control circuit scales the electrical signals and converts the signals to binary numbers having magnitude bits and a polarity bit respectively. The binary numbers, representing the signals, are simultaneously shifted into a logic processor for calculation of a feedback signal based on the digitized input. The feedback signal is calculated based on the polarity of connectivity of the remote welding sense leads as represented by the binary numbers. The feedback signal is then fed into the power supply output controller for automatically adjusting the power output of the arc welder.

Abstract: A welding-type power supply includes a controller, a preregulator, a preregulator bus, and an output converter. The controller has a preregulator control output and an output converter control output. The controller has a converter control output connected to the control input, and a flux balancing module. The converter control output is responsive to the flux balancing module such that the flux in the transformer remains balanced.

Abstract: Nonlinear adaptive welders and power source controls are provided along with welding methods method for regulating a welding process, in which one or more welding waveform parameters are adapted in nonlinear fashion based on measured welding process feedback information.

Abstract: Methods and systems for manufacturing and using the auxiliary power conversion unit, which is capable of being remotely located from a welding power supply unit during a welding operation, are provided. In some embodiments, the auxiliary power conversion is capable of outputting DC as well as AC power, capable of outputting multiple voltages consistent with the demands of typical auxiliary tools, such as a hand grinder or a light. In certain embodiments, the power conversion unit may be a stand-alone system or may be incorporated into a device, such as a wire feeder, which is configured to derive power from the arc potential. The power conversion unit may contain control and processing electronics that may include a controller, a processor, memory, and so forth.

Abstract: An electric arc welding system for depositing weld metal along a groove between two edges of a metal workpiece where the system contains a first power supply and a second power supply, each providing a welding waveform to respective welding electrodes. The positive output terminals of both power supplies are coupled to the same contact tip and the negative output terminal of one of the power supplies is not coupled to the workpiece.

Abstract: A technique for dynamically adjusting an output voltage for a welding or cutting operation is provided. The technique allows for varying output voltage at the welding or cutting torch by manipulating the duty cycles of two forward converter circuits. The present disclosure provides methods and systems for increasing synchronized duty cycles in a pair of forward converter circuits in response to increasing output voltage demand then changing a phase shift between the duty cycles in response to further increases in output voltage demand. The present disclosure provides a controller designed to receive input signals and generate output pulse width modulation signals that control the duty cycle width and phase shift of the outputs of the forward converter circuits in response to these signals. Methods of accommodating for the time needed for the transformer core to reset via leading edge or lagging edge compensation are provided.

Abstract: A welding apparatus comprises a welding unit for welding a workpiece. The welding unit comprises a welding assistance system for generating control commands by evaluating a voice dialogue performed with a welder, and a weld control unit for setting weld control parameters in dependence upon the control commands. A welding system includes a plurality of such welding apparatuses, wherein the welding assistance system is connected to the weld control units of the welding apparatuses via a data network. A method for welding a workpiece by means of a welding unit comprises providing a welding assistance system, evaluating a voice dialogue performed with a welder operating the welding unit, producing control commands for a weld control unit, and setting weld control parameters in dependence upon the produced control commands.

Abstract: Welding systems are presented, in which a single power source provides a first DC output to a plurality of digital waveform controlled chopper modules. Welding modules are also disclosed for converting an input DC signal to a welding signal, which are comprised of a down-chopper for providing a welding signal waveform according to a pulse width modulated switching signal, along with a digital waveform controller providing the switching signal according to a desired waveform.

Abstract: Systems and methods are provided for a torch power system using a multi-stage compressor. In one embodiment, a system includes a torch power unit that includes a compressor having multiple compression stages. A method of operation is provided that includes compressing a gas via a multi-stage compressor in a torch power unit. A method of manufacturing a torch power unit is provided that includes providing a multi-stage compressor for a torch power unit and mounting the multi-stage compressor inside an enclosure of the torch power unit. Another system is provided that includes a plasma cutting circuit, a multi-stage compressor, a motor coupled to the compressor, and a compressor controller.

Abstract: A system includes a power supply, a first cable assembly, and a second cable assembly. The power supply includes a housing and supports extending from an upper portion of the housing. The first cable assembly has a clamp disposed at a distal end of a first cable extending from the power supply. The clamp is configured to be removably coupled with a workpiece. The second cable assembly has a torch disposed at a distal end of a second cable extending from the power supply. The housing includes one or more sloped panels configured to hold the first and second cables in a position wrapped about the upper portion of the housing when the clamp and the torch are coupled to the supports.

Abstract: An arc welding power supply supplies power to a welding wire functioning as a discharge electrode to generate an arc from an electrode distal end of the welding wire and perform arc welding on a welded article. The arc welding power supply includes an output control unit that adjusts the power supplied to the welding wire to a power value suitable for arc welding. A feed control unit cyclically changes a feeding speed of the welding wire. The feeding speed includes a forward feeding speed and a rearward feeding speed. An amplitude control unit cyclically changes an amplitude of the feeding speed of the welding wire to cyclically vary an average arc length.

Abstract: A power supply for use in a welding or cutting system includes a housing configured to hold circuitry of the power supply. The housing includes clips at one or more corners of the housing. The clips are configured to receive and hold a cable when the cable is wrapped around the housing. The cable is coupled to and extending from the power supply.

Abstract: A system and method for an integrated structural welding system is designed to protect improve work flow efficiency. Specifically, a welding-type power source is provided that is free of user interface devices designed to select power parameters. Instead, a wire feeder is provided that includes a user interface configured to receive operational and power parameters and a controller configured to control operation of the welding-type power source based on the feedback received through the user interface.