Abstract: A system and method for determining settings or parameters for a welding-type power source are provided. By presenting an operator with an interface that is positioned along the path of a weld cable and configured to input weld characteristics, an operator is not required to determine electrical parameters for setting a welding-type power source output at the power source. The interface is presented to the operator at a remote welding-type device, such as a wire feeder, a weld robot, a torch, or the like. From the operator-specified weld characteristics, the system and method determine appropriate settings for the power source. In some embodiments, the system and method may automatically set the power source accordingly.

Abstract: A method of operating a welding power supply (20) during a welding process in which an electric arc (95) between a consumable electrode (94) and a work piece (102) is generated while feeding the consumable electrode (94) and moving the arc (95) in relation to the work piece (102) along a welding track (103), wherein a transition between a DC power output of the welding power supply and an AC power output of the welding power supply, or vice versa, is made without interruption of the welding process.

Abstract: A welding power supply includes a switching type power converter. A welding electrode is connected to the power converter to receive electrical energy therefrom and produce an electric arc. An engine-generator is connected to the welding power supply to supply electrical energy for producing the arc. The engine-generator comprises a plurality of armature windings, and a field winding. A battery is connected to the welding power supply to simultaneously supply further electrical energy for producing the arc, and to receive electrical energy from the engine-generator through the power supply to recharge the battery. A sensor senses battery voltage and/or current, and outputs a signal during recharging corresponding to the battery voltage and/or current. A field controller is connected to the field winding and to the sensor. The field controller receives the signal from the sensor and automatically adjusts a level of current flow through the field winding during recharging based on the signal from the sensor.

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: An arc welding control method for carrying out welding by generating an arc between a wire and a base material. The wire is fed at wire feed speed (Wf) of periodically repeating forward feeding and reverse feeding with predetermined frequency and amplitude from time point (100) at which start of the welding is instructed, or from a certain time point (101) after the start of the welding is instructed, and then the wire feed speed is changed to a constant speed. Since the wire feed speed is controlled by periodically repeating forward feeding and reverse feeding at the arc start, short-circuit can be opened regardless of the electromagnetic pinch force, and spatters, which are generated at the early stage of the arc start because a molten pool is not preset, can be reduced.

Abstract: Systems and methods for affecting an appearance of a deposited weld bead by modulating one or more welding parameters. For example, an electrode negative portion of a welding output current may be modulated to affect the appearance of a deposited weld bead. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with an electrode negative portion of a welding output current to affect a deposited weld bead appearance. Two or more welding processes may be interleaved with each other at a specified modulation frequency to affect a deposited weld bead appearance. One or more welding parameters may be modulated based on a welding travel speed to provide a consistent appearance of a deposited weld bead.

Abstract: A welding system is disclosed for performing a short arc welding process between an advancing wire electrode and a workpiece. The system comprises a power source with a controller for creating a current pulse introducing energy into the electrode to melt the end of the electrode and a low current quiescent metal transfer section following the end of the melting pulse during which the melted electrode short circuits against the workpiece; a timer to measure the actual time between the end of the pulse and the short circuit; a device for setting a desired time from the pulse to the short circuit; a circuit to create a corrective signal based upon the difference between the actual time and the desired time; and, a circuit responsive to the corrective signal to control a given parameter of the current pulse. Also disclosed is a strategy for arc welding utilizing a cored electrode that produces welds with low levels of contaminants and which are strong, tough, and durable.

Abstract: The system provides both a portable and appliance welding system. It can be use in the shop and field. In either location it can be plugged in or battery driven. When plugged in it can weld while charging simultaneously offering 100% duty cycle for heavy shop use, and a full range of metal thicknesses can be welded with ease. The system is implemented with a solid state high energy circuit; unrestricted and unfiltered, offering a wide spectrum of pure analog power. The systems is compact for maximum portability and use in remote field operations, yet can handle deep welds in a variety of metal compositions, conditions, environments, and sizes. The system uses a proven and robust storage medium of direct electric potential energy that is supplied by industrial batteries.

Abstract: A welding-type device has a wireless communication unit to transmit wireless signals comprising at least identification information or location information. The information may be transmitted either automatically or in response to request signals. Such a welding-type device may be configured to communicate with other welding-type devices, a monitoring device, or both. A wireless communication system has at least one welding-type device, at least one wireless communication assembly, and at least one monitoring device and is capable of assisting a user in locating particular welding-type devices, monitoring inventory, preventing theft of welding-type devices, and scheduling preventive maintenance.

Abstract: Systems and methods for providing controlled AC arc welding processes. In arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from a consumable electrode to a workpiece and further aids in the maintaining or the re-establishing of an arc between the consumable electrode and the workpiece when a molten metal ball is transferred.

Abstract: Systems and methods for providing controlled AC TIG arc welding processes is provided. In AC TIG arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from consumable to a workpiece, via an arc generated by a tungsten electrode, and further aids in the maintaining or the re-establishing of an arc between the tungsten electrode and the workpiece during welding.

Abstract: The present invention includes a welding system that has at least two metal inert gas (MIG) welders configured to perform a cooperative pulsed MIG welding process. The welding system also includes at least one communications link connecting the at least two MIG welders to deliver at least one of subordination commands and superiority commands to either of the at least two MIG welders to synchronize the cooperative pulsed MIG welding process.

Abstract: The invention is a welding method capable of controlling an arc heat distribution on a groove face of a base metal, which comprises increasing or decreasing the melting rate of a welding wire relative to the feeding rate of the welding wire by changing the characteristic of an arc current to thereby change an arc generating position of a fusing end of the welding wire, wherein an AC arc welding operation is performed by changing the polarity of the welding wire as the characteristic of the arc current; and a welded joint structure formed by the welding method.

Abstract: The invention provides a high flow power cable for a welding system designed for effective cooling of the power cable while maintaining maneuverability of the cable. Provided is a power cable having two segments, the first segment being larger in diameter than the second segment. The first segment is generally coupled to the power source and the second segment is coupled to the welding torch. The first segment includes a thicker wire, which has less resistance and dissipates less heat while the second segment includes a thinner wire, allowing for easier handling. Additionally, cooling fluid is conducted through the first segment and the second segment, further cooling the cable.

Abstract: A system and method for operating an inverted-based power source includes a power input configured to receive alternating current (AC) power and a rectifier configured to convert the AC power to direct current (DC) power. The inverter-based power source also includes an inverter configured to receive the DC power from the rectifier and convert the DC power to AC power and a controller configured to generate switching signals according to a pattern of offsets from a regular half period and communicate the switching signals to the inverter or rectifier control operation of the inverter or rectifier.

Abstract: Embodiments of a pendant associated with a multi-process welding power supply that allows a user to switch processes and reverse an output polarity while located remotely from a power supply unit are provided. Certain embodiments include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Control circuitry that may include processing circuitry and memory is provided. The control system may disable redundant controls on the power supply unit user interface when the power supply unit is connected to the pendant via a supply cable. Additionally, the control system may set the process, set the polarity, enable or disable a wire feed, and enable or disable gas flow according to inputs received via a user interface on either the power supply unit or the pendant.

Abstract: The invention relates to an electronic circuit and a method for feeding power to at least one electrode of an alternating-current electric-arc furnace, particularly for melting metal. Known circuits of this type typically comprise a series connection with a transformer for providing a supply voltage for the electric-arc furnace from a power grid (1) and a AC power controller (8) connected between the transformer (6) and the electrode (11) for regulating the current through the electrode (11). According to the invention, a further development for such electronic circuits is proposed, which development has a simple design, is inexpensive and prevents overload of the AC power controller (8) even in operating modes of the electric-arc furnaces at high electrode currents. This further development provides to bypass the AC power controller with a bypass switch (9) that is opened or closed with the help of a controller as a function of the amount of current flowing through the electrode (11).

Abstract: An arc welding apparatus includes a main power supply circuit for outputting an arc current, a control circuit for controlling the main power supply circuit, and a high-frequency voltage generating circuit for generating a high-frequency voltage. When an operation switch is turned on for a first time since the apparatus is powered on, the control circuit activates the main power supply circuit to output a high voltage, and the high-frequency voltage generating circuit to generate a high-frequency voltage. With the high voltage superimposed on the high-frequency voltage, the control circuit passes a welding arc current through a torch and a base material. The switch is then turned off, and the control circuit passes a pilot arc current through the torch and the base material. The switch is turned on again, and the control circuit activates the main power supply circuit to output a high voltage, thereby allowing smooth arc transition.

Abstract: A welding-type system is designed for wireless control and for inventory monitoring of welding consumables. The welding-type system includes a power source to produce a welding-type power, wherein the power source is operable in a plurality of operating modes. The welding-type system also includes a controller configured to set a plurality of operating parameters within the power source, at least one wireless monitoring device coupled to the controller, and at least one welding-type consumable associated with a wireless transmitter. The wireless transmitter is configured to emit low frequency magnetic signals having consumable data encoded therein that is indicative of the at least one welding-type consumable. The wireless monitoring device is arranged to communicate with the wireless transmitter by receiving and transmitting the low frequency magnetic signals, with the low frequency magnetic signals being transmitted at a frequency of approximately 131 kHz.

Abstract: A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other.

Abstract: A welding power supply unit includes an outer enclosure having a plurality of sides that encompass internal components of the welding power supply unit. The welding power supply unit also includes a roll cage assembly having a plurality of roll bars. Each roll bar is disposed generally parallel with, but not adjacent to, an edge of a side of the outer enclosure and external to the outer enclosure. At least two of the roll bars are associated with handle portions that rotate with respect to the respective roll bar. Each handle portion includes an extruded tubular aluminum bracket or a die cast aluminum bracket disposed around its respective roll bar. In addition, the welding power supply unit includes a plurality of fastening mechanisms attached to the outer enclosure, the fastening mechanisms securing the roll cage assembly to the outer enclosure.

Abstract: A low voltage, low inductance power supply for supplying a current through a filler wire in order to resistance-heat at least an extended portion of the filler wire. The power supply is configured to have an output inductance in a range of 40 to 70 micro henries, a saturation current in a range of 20 to 50 amps, and an open circuit voltage that is less than or equal to 13 volts.

Abstract: Welding apparatus includes a welding machine that generates welding electric power and an input unit that includes input switches for controlling the operations of the welding machine. The welding apparatus also includes a wireless receiver unit that is electrically connected to the inputs of the input unit to receive wireless instructions for controlling the operations of the welding machine.

Abstract: A weld data acquisition system collects data from the weld controller according to user selected collection parameters. The weld data acquisition system is able to transmit the data at high frequency to a weld data software utility that provides a user interface.

Abstract: A welding system including a housing forming an enclosure, a power supply arranged within the enclosure and configured to deliver welding-type power during a welding-type process, a user interface including at least one user interface device configured to select operational parameters of a welding process that includes a touch-responsive display element configured to indicate a desired setting of the at least one user interface device in response to contact by a hand of a user, and a bezel forming a marking surface associated with the at least one user interface device to display user markings and allow the user markings to be selectively erased, wherein the marking surface is proximate to the touch-responsive display element.

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 preregulator receives a range of inputs voltages as a power input, and receives the preregulator control output as a control input, and provides a preregulator power output signal. The preregulator includes a plurality of stacked boost circuits. The preregulator bus receives the preregulator output signal. The output converter receives the preregulator bus as a power signal and receives the output converter control output as a control input. The output converter provides a welding type power output, and includes at least one stacked inverter circuit.

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: A method and system with a welding torch having a contact tip which has an upper portion and a lower portion, where the upper portion and the lower portion are electrically isolated from each other and each of the upper portion and the lower portion make contact with the same electrode during a welding operation. A first power supply is coupled to the upper portion which provides a first current to the upper portion during the welding operation, and a second power supply is coupled to the second portion which provides a second current during the welding operation. The first and second currents are accumulated in the electrode during welding to provide a welding waveform. The first power supply can have a higher inductance than the second power supply.

Abstract: Methods and systems for feeding a rod of filler wire to a welding operation are provided. For instance, a handheld filler wire advancement device is provided. The device includes a casing having an opening extending axially through the casing for receiving a rod of filler wire. The device also includes a drive assembly disposed within the casing and adapted to contact the rod of filler wire to advance and retract the rod of filler wire within the opening of the casing. Further, the device includes a motor disposed within the casing and coupled to the drive assembly to provide the drive assembly with power for movement of the rod of filler wire.

Abstract: A welding system, in certain embodiments, includes a synchronization controller configured to override a first nominal calibration of a first wire drive, or a second nominal calibration of a second wire drive, or both, in response to a tension condition or a compression condition of a welding wire feeding between the first and second wire drives. A welding system, in other embodiments, includes a welding wire drive having a motor, a controller, a nominal calibration, and a multi-drive synchronization parameter. The multi-drive synchronization parameter may be configured to control speed, or torque, or both, of multiple drives including the welding wire drive to facilitate synchronization of the multiple drives.

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

Abstract: An arc welding system includes a welding torch, an electrode, and a power supply having a switching-type power converter connected to the torch. A parallel state-based controller is connected to the power converter and provides a waveform control signal thereto for controlling its operations. The controller generates a motion control signal for controlling movements of the electrode and/or the torch. A sensor senses welding voltage or welding current. A memory stores a welding state table comprising sequential control states, and stores a motion control system state table comprising further sequential control states. The welding waveform is defined in the welding state table. The controller controls the operations of the power converter through the waveform control signal according to the welding state table, simultaneously adjusting the motion control signal according to the motion control system state table. The controller transitions between control states according to the signal received from the sensor.

Abstract: A welding-type component is disclosed having a single user input that requires a user to input only a single parameter to identify a welding-type process. From the single input, operating parameters for the welding-type process automatically are set or otherwise determined. The invention streamlines the welding-type process prescription process by allowing a user to input only a single parameter than can be used to determine and coordinate other parameters for the welding-type process.

Abstract: A method for root pass welding steel plate and pipe is provided that uses pulse arc welding having a current pulse waveform exhibiting a low constant background current and fixed frequency. The welding process may be performed without a backer or backing material.

Abstract: A welding system component includes a circuit board for the welding system component. An interface has a main riser portion with a fastener passageway formed therethrough. The interface has an extension portion with a terminal passageway formed therethrough. The extension portion is electrically connected to the circuit board with a terminal disposed in the terminal passageway. The extension portion is spaced away from a surface of the circuit board. A capacitor is electrically connected to the main riser portion with a fastener disposed in the fastener passageway.

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: An improvement in a welder including a power source for performing a TIG welding process across an electrode and a workpiece where the power source has a first output lead connected to the electrode and a second output lead connected to the workpiece with a controller for creating a waveform across the power leads. The waveform has a profile alternating between a first current section and a second current section at a given overall frequency and the sections each have a peak current in either the positive or negative direction and a duration. The improvement comprises at least one of the current sections being pulsed between a high current level equal to its peak current and a low current level in the opposite direction of the peak current at a pulsing frequency greater than the given overall frequency.

Abstract: A system and method for determining a wear condition of a welding consumable includes a welding torch having a consumable component and a wire delivery system configured to deliver wire to the welding torch during a welding process. The welding system also includes a power source configured to deliver power to the welding torch to perform the welding process. A controller is included that is configured to monitor at least one operational characteristic of the delivery of wire to the welding torch over a selected period, determine a wear condition of the consumable component from the at least one operational characteristic, and generate a signal indicating detection of the wear condition.

Abstract: A polarity switching control method is provided for consumable electrode AC pulse arc welding. By the method, a peak current and a base current are applied during an electrode-positive polarity period, while an electrode-negative current is applied during an electrode-negative polarity period. For performing the welding, polarity switching is performed to alternate the electrode-positive polarity period and the electrode-negative polarity period. When a consumable electrode and a base metal are in short circuit with each other, the polarity switching is performed after the short circuit is broken and an arc is generated.

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: A three stage power source for an electric arc welding process comprising 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, a network of switches switched at a high frequency with a given duty cycle to convert the input into a first internal AC signal, an isolation transformer with a primary winding driven by the first internal high frequency AC signal and a secondary winding for creating a second internal high frequency AC signal and a rectifier to convert the second internal AC signal into a second DC output signal of the second stage, with a magnitude related to the duty cycle of the switches; and, a third stage to convert the second DC output signal to a welding output for welding wherein the input stage has a regulated DC to DC converter with a boost power switch having an active soft switching circuit.

Abstract: A system and method for identifying, recording, and storing specific settings for an interface device of a welding-type system includes a bezel forming a marking surface that extends about a portion of a periphery of the interface device to display user markings and allow the markings to be selectively erased. The marking surface may be designed to receive color-coded markers that engage the marking surface through suction, magnetism, or peg-and-receptacle couplings to indicate desired settings of the interface device to perform a specific welding-type process. Additionally, if the interface device is a dial, a pointer may be coupled with the dial that is movable independently from the dial to indicate a desired dial setting.

Abstract: An arc welding power source supplies a start current, a welding current and a crater current as an output current in accordance with an activating signal supplied from outside. The power source includes a start period setting unit, a crater period setting unit, and a current control unit that controls the output current. The current control unit causes the power source to supply the start current and the welding current consecutively while the activating signal is in an on-state, where the start current is supplied for the start period, and the welding current is supplied for the period following the start period. The current control unit also causes the power source to supply the crater current after the activating signal is turned off, where the crater current is supplied for the crater period.

Abstract: Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

Abstract: A welding system including a fine tuning knob and a coarse adjustment knob for setting a weld wire feed speed are provided. The welding system may include a welder having the coarse adjustment knob and a spool gun having the fine tuning knob. A user may adjust the knob on the welder to set a coarse adjustment wire feed speed and may adjust the knob on the spool gun to fine tune the wire feed speed setting.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: A welding apparatus having a system to facilitate its assembly. The apparatus is assembled by affixing a pair of molded end panels to a molded base and each of the end panels has a specially constructed receptacle area that is adapted to receive an end of the base. Each end of the base has a pair of snaps that extend outwardly and which engage with a correspondingly located pair of ramps formed in the receptacle area of each of the end panels. Thus the assembly is easily carried out by simply inserting the base ends into the receptacle areas where the snaps ride up the ramps and engage the vertical walls on the inner side of those ramps to securely affix the end panels to the base. Preferably the snaps are U-shaped in configuration with the distal end of the snaps being the closed ends of the U-shaped snaps.

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

Abstract: A method and apparatus for providing welding-type power is disclosed and includes a means for communicating.

Abstract: A system and method for powering a welding-type device from a plurality of distinct outlet configurations is disclosed. The power cord system includes a power cord having a plurality of conductors extending therethrough. An end of the power cord is constructed to engage an individual adapter of a plurality of adapters. Each of the plurality of adapters has a prong configuration that is different than a prong configuration of the other adapters such that each of the plurality of adapters is constructed to electrically connect the power cord to a uniquely configured outlet. A welding-type device according to the present invention is quickly and efficiently adaptable to operate at a plurality of different input power signals.