Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding electrode. The power source comprises a positive stud and a negative stud. The welding system also includes control circuitry configured to determine whether the welding electrode is properly connected to the positive and negative studs of the power source.

Abstract: Purge gas apparatus and method for a welding system uses automatic purge gas flow control function, such as an MFC, to control ID and/or OD purge gas flow rate or purge gas pressure or both at the weld site.

Abstract: A power module cartridge for a welder includes a chassis tray that is dimensioned to fit inside an external case of the welder. The chassis tray includes a fan receptacle, a capacitor receptacle, a rectifier mounting slot and a transformer receptacle. A fan fits into the fan receptacle; a capacitor fits into the capacitor receptacle; a rectifier plate fits into the rectifier mounting slot; and a transformer fits into the transformer receptacle. The chassis tray can also include a clip for receiving a printed circuit board (“PCB”). The PCB can be electrically connected to the aforementioned components. A second chassis tray can fit on the top of each of the components such that the components are sandwiched between the first and second chassis trays. A method of manufacturing a welder is also disclosed.

Abstract: Welding systems and programming tools are described, in which a touch screen-based welding system configuration tool is provided having a touch screen display for designing welding power source waveforms or for configuring a system sequence controller, where the touch screen may be integrated into a welding system component. The touch screen displays information related to a switching type welding power source and/or a welding system sequence controller, as well as one or more touch activation indicia to allow a user to numerically or graphically configure the power source or the sequence controller by touching the touch activation indicia.

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: An alternating current-to-direct current (AC-to-DC) power supply has a first stage providing a first DC voltage and a second stage providing a second DC voltage. The AC-to-DC power supply has a first efficiency at the first stage and a second efficiency at the second stage that is less than the first efficiency. The second DC voltage is also less than the first DC voltage. A blower is electrically connected to the first stage of the AC-to-DC power supply to receive the first DC voltage from the AC-to-DC power supply to power the blower. Electrical connection of the blower to the first stage of the AC-to-DC power supply instead of to the second stage of the AC-to-DC power supply wastes less power and is more efficient.

Abstract: A system and method is provided in which at least two welding power supplies are coupled to respective weld torches where the power supplies each provide a pulse welding waveform to their respective weld torches such that the welding pulses are out of phase with each other such that the respective welding pulses do not overlap during welding. The system also includes a ground current switch which switches the ground current path during welding to minimize arc interference and arc blow.

Abstract: A method and device for controlling current flow through a welding clamp are provided. One welding clamp includes a first contact piece configured to contact a workpiece and to provide a first current path that limits current flow. The welding clamp also includes a second contact piece configured to contact the workpiece and to provide a second current path. When the welding clamp is being clamped to the workpiece, the first contact piece is configured to contact the workpiece prior to the second contact piece. In addition, the welding clamp is configured so that current flows through the first current path prior to flowing through the second current path when the welding clamp is being clamped to the workpiece.

Abstract: A TIG welder and methodologies for providing an output welding current in a welding circuit. The welder has main and background power supplies. The main supply has an SCR network which selectively connects a transformer secondary winding to the welding circuit according to SCR control signals. The background supply is connected to the SCR network, which selectively connects the second power supply to the welding circuit according to the SCR control signals. The SCR network may have first and second SCRs operating according to first and second SCR control signals from a control circuit, where the control circuit is connected to the SCR network and the second power supply and selectively connects the SCR control signals to the SCR network according to the setpoint current value.

Abstract: A welding operation is performed by moving or rotating an arc in a welding torch, and feeding a metal cored wire through the torch in a direct current, electrode negative welding process. The electrode may include one or more arc stabilizers. The welding process may be pulsed or non-pulsed. Moreover, the process may be used with a number of different base metals intended to be welded, such as thin plate, galvanized metals, painted metals, coated metals, and so forth.

Abstract: An engine driven welding system includes two power generators, each having a rotor and a stator. Each rotor is mounted on a respective drive shaft, with one of the drive shafts being driven by the engine and the other drive shaft being releasably coupled to the engine driven drive shaft. This provides a modular type construction of the welding system, in that the outboard power generator can be selected or changed as needed for a particular application. The coupled drive shafts are supported by two bearing assemblies. Also disclosed as additional features for any welding system power supply is a removable plate having one or more connectors releasably attached thereto for facilitating installation of an electrical component for a welding system power supply; and also a power switch having a member that restricts rotational movement of the switch.

Abstract: A power supply apparatus includes an air path extending longitudinally, a fan that blows air into the air path in a direction intersecting a longitudinal direction of the air path, and a plurality of electronic components arranged in the longitudinal direction. Each of the electronic components is cooled by air passing through the air path. With this configuration, it is possible to efficiently cool the electronic components without compromising the flexibility of arrangement of the various electronic components. Also, a dust removal operation can be readily performed without the possibility of damaging the fan.

Abstract: A welding power supply includes a controller that automatically monitors the presence or absence of one or more modules connected to or installed into the welding power supply. The controller automatically turns on or off the power supply functions related to which optional modules are present. The controller populates various end-user interface menus based on which optional modules are installed. The controller uses software and/or hardware to make the determination. The optional module(s) themselves include circuitry which allows the controller to recognize when the optional module has been installed and what functions the installed optional module is capable of performing. The circuitry of the optional module(s) allows the optional module(s) to communicate with the controller. In this way, the end-user will not have the options of selecting a process on the user interface menus that is not available because the required equipment has not been installed.

Abstract: A welding assembly including a current generator, an electrode electrically coupled to the current generator, the electrode including a first engagement surface, and a workpiece including at least two members, wherein at least one of the members includes a second engagement surface, defines a recess in the second engagement surface, and is electrically coupled to the current generator.

Abstract: A mobile welding system has a mobile base for traversing a surface, proximate to a region to be welded. The mobile welding system has a lift, coupled to the mobile base and to a platform for moving the platform vertically proximate to the region. The lift is disposed between the platform and the mobile base. The mobile welding system has a robotic arm coupled to the platform. The mobile welding system has a welding torch, disposed on a first end of the robotic arm, for welding the region. The mobile welding system has a controller configured to cause the welding torch to move proximate to the region by causing at least one of the mobile base, the lift, and the robotic arm to move in at least one direction.

Abstract: A method of controlling a power source includes providing a power supply module. The power supply module includes a first circuit that has at least one first switch. The first circuit is configured to provide a welding current to an electrode of a welding system. The power supply module also has a second circuit that includes a load that is operatively connected to at least one second switch. The second circuit is configured to provide the welding current to the electrode through the load. The method also includes controlling the at least one first switch such that the welding current flows through the at least one first switch and to the electrode during a ramp up portion of a welding waveform and such that no current flows through the at least one first switch during a ramp down portion of the welding waveform. The method further includes controlling the at least one second switch such that the welding current flows through the load and to the electrode during the ramp down portion of the welding waveform.

Abstract: A welding control unit has a common power section for detecting contact of a welding material and for welding. A material contact detector for detecting contact of the welding material and a workpiece, and a power controller are built in the welding control unit. This stabilizes a bead shape in starting welding. The number of components can also be reduced, resulting in more inexpensive equipment. In addition, only a space for installing the welding control unit is needed without any additional space.

Abstract: A welding or cutting system having a power supply with no user interface hardware or software for controlling the operation of the power supply, and a mobile communication device which contains an application allowing for control of the power supply. The mobile device is coupled to the power supply through either a wired or wireless connection.

Abstract: A welder includes a housing enclosing one or more welding circuits communicated with power output studs for establishing a welding arc. A generally rigid bracket may be included that is affixed to an exterior of the housing, which may include first and second spaced apart support arms extending from a bracket, where the first support arm includes a first supporting surface facing a first direction, and where the second support arm includes a second supporting surface facing a second opposite direction for supporting the associated welding gun in a cantilevered configuration. A cable cradle is also included that extends from a second, distal end of the bracket.

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 capacitor discharge (CD) fastener welding circuit including: an input voltage source; a rectifier bridge of diodes receiving the input voltage source; at least two capacitor charge switches linked with the rectifier bridge; at least one capacitor linked with the at least two capacitor charge switches; and at least two capacitor discharge switches linked with the capacitor and to welding output terminals.

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 drawn arc welding device includes a welding tool, and an energy storage device coupled to a power source. A charging circuit is connected to the energy storage device replenishing the storage device. A discharge circuit is connected to the welding tool and energy storage device. The discharge circuit regulates and adjusts a welding current of the welding tool to a specified amount. Also disclosed is a process that includes charging the energy storage device, actuating the welding tool, energizing a pilot arc current, lifting the weld stud off a workpiece to draw the pilot arc, energizing a welding arc wherein the discharge circuit regulates a welding current of the welding tool to a specified amount, and plunging the weld stud into the workpiece and turning off the discharge circuit.

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: The invention relates to a welding method for implementing and monitoring a welding process, whereby a power source (2) and a feeding device (10) for the welding rod (11) are controlled by means of a control device (4), and whereby at least one control variable is measured or calculated from characteristic variables of the arc during the welding process.

Abstract: An arc start control method in robot welding includes the steps of shorting a welding wire with a base metal, retracting a welding torch by a welding robot for taking the welding wire off the base metal to generate an initial arc, retracting the welding torch to a predetermined position with maintaining the initial arc maintained while applying an initial arc current smaller than a steady welding current during this initial arc period, and starting to feed the welding wire steadily and to supply the steady welding current so as to make a transition from the initial arc to a steady arc as well as starting to move the welding torch along a welding line. During a re-shorting prevention period which starts from a beginning of the initial arc period, a re-shorting prevention current which is larger than the initial arc current is applied in order to prevent re-shortening between the wire tip and the base metal right after the initial arc was generated. Thereafter, the initial arc current is applied.

Abstract: A two-electrode arc welding device and two-electrode arc welding method are provided for performing welding with improved penetration performance using two non-consumable electrodes. In a two-electrode arc welding device, a power-supply unit outputs a straight-polarity voltage and a reverse-polarity voltage, which has a different electrical potential than the straight-polarity voltage. The straight-polarity voltage output from the power-supply unit is applied to a non-consumable electrode of a straight-polarity arc torch, whereby an arc is formed. The reverse-polarity voltage output from the power-supply unit is applied to a non-consumable electrode of a straight-polarity arc torch, whereby an arc is formed. An arc spacing distance, which is a distance between the ends of both the straight-polarity arc torch and the reverse-polarity arc torch, is set to be at least a minimum distance at which an arc will not occur therebetween (arc spacing critical distance).

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 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 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 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 system includes components equipped with digital communications circuitry for synchronization and coordination of tasks associated with the welding operation. The tasks may be initiated and terminated independently or in coordination based upon synchronization of this circuitry. Certain of the tasks may be performed by the components in an open-loop manner or in a closed-loop manner based upon feedback of welding parameters. Moreover, certain tasks may be independent of one another, or interdependent although carried out in parallel by the different system component.

Abstract: A portable plasma arc torch system can be used for processing materials. The system includes a replaceable or rechargeable power source and replaceable or rechargeable gas source. A controller communicates with at least one of the power source or the gas source. A plasma delivery device received via the controller current from the power source and gas from the gas source to generate a plasma arc at an output of the plasma delivery device. The plasma arc can be used to process materials such as metallic workpieces. The plasma arc torch can include a wearable portable assembly which includes the replaceable or rechargeable power and gas source. A plasma delivery device receives current from the power source in the assembly and gas from the gas source in the assembly to generate a plasma arc.

Abstract: A high power disintegrator system comprising a master disintegrator unit and a power booster disintegrator unit, the units being connectable in parallel to a common electrode, each unit including a cutting transformer and an adjustable auto transformer arranged to supply an adjustable voltage to its cutting transformer, an electrical control circuit responsive to voltage detected in the power booster unit that prevents operation of the booster unit when the auto transformers are set to produce different voltages at their respective cutting transformer.

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: 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 for of a second DC output signal electrically isolated from the first DC output signal end 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: A system and method for generating a weld are provided. The system receives a selection of a magnitude of a voltage. The system selects a first weld control algorithm when the magnitude of the voltage is in a first range of values. The system may also select a second weld control algorithm when the magnitude of the voltage is in a second range of values. The system may generate welding output power based on the first and second weld control algorithms.

Abstract: An arc welding system includes a wire feeding mechanism for delivering welding wire to a welding operation, and a welding power supply for generating a current for welding to the welding wire. The welding wire includes at least two distinct types of welding electrodes.

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 power source includes a primary inverter configured to generate a first AC power and a transformer having a primary side configured to receive the first AC power and a secondary side configured to deliver a second AC power. The welding-type power source further includes a converter configured to convert the second AC power to DC power and a half-bridge inverter configured to receive the DC power and having a first output and second output configured to deliver respective portions of an AC welding-type power to a welding output to generate a welding-type arc during a welding-type process. An inductance is connected at a first end to the first output and the second output of the half-bridge inverter and connected at a second end to the welding output.

Abstract: A welding system including a welding power supply coupled to a wire feeder via a spool gun connection is provided. The welding system is adapted to utilize the power and control capabilities originating from the spool gun connection for wire feeder operations during an initial period. The wire feeder is adapted to utilize the welding arc power and an internal controller to power and control wire feeder operations after the initial period.

Abstract: An electric arc welder includes a short detecting circuit for creating a short signal upon occurrence of a short circuit between an advancing electrode and a workpiece, and a boost circuit to create a plasma boost pulse after the short circuit is cleared during the time period when the welder is not outputting a peak pulse current.

Abstract: The invention provides a compact and economical welding control system having an integrated power section. To this end, a switching module is provided for the power section of a welding control system. The switching module has a switching device, at least one cooling body, a current supply and an insulating element which provides a potential-free coolant arrangement. The invention is advantageous in that the potential-free coolant arrangement allows the coolant bodies to be shortened so that less space is required inside the control system and the control system can therefore have a more compact structure. The invention enables even the requirements in terms of the coolant bodies to be reduced, allowing the use of cost-effective cooling tubes or even cooling pipes that are directly connected to the cooling body.

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 for welding a work-piece includes an energy source configured to generate a weld in a zone of the work-piece, with the work-piece characterized by a layer. The apparatus also includes a first wheel characterized by a first circumference and a first set of protrusions disposed on the first circumference, and a second wheel characterized by a second circumference and a second set of protrusions disposed on the second circumference. Each of the first and second wheels is configured to rotate relative to the work-piece, and the first and second sets of protrusions are configured to disrupt the layer as the work-piece is traversed between the first and second wheels. The energy source generates the weld in the zone of the work-piece following the disruption of the layer. A method employing the disclosed welding apparatus is also provided.

Abstract: A method for adjusting multiple settings of a welding power supply is provided. The method includes providing a plurality of selectable identifiers. Each selectable identifier corresponds to a plurality of user adjustable welding power supply settings. The method also includes receiving an indication to select one of the plurality of selectable identifiers. The method includes adjusting the plurality of user adjustable welding power supply settings that correspond to the received indication.

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: A weld current generating apparatus includes a voltage conversion circuit, a control circuit, and a charge/discharge circuit. The voltage conversion circuit receives an AC voltage from an AC voltage input terminal and converts the AC voltage to a DC voltage. The control circuit receives the DC voltage and outputs control signals. The charge/discharge circuit receives the DC voltage and is charged by the DC voltage or discharged according to the control signals. The charge/discharge circuit outputs a continuous weld current during discharging process.

Abstract: An electric arc welder power supply housing assembly is described in which it is possible to clean internal component parts is achieved by positioning cooling components on a rail system. The rail system may include at least one telescoping track assembly. When the telescoping track assembly is engaged, the housing assembly is in an open position, thus providing access for the maintenance of internal components therein without having to disassemble unnecessary components or parts of the welding power supply.

Abstract: A welding system is provided, in which two electrodes are directed at a joint between two work pieces and the electrodes are energized with DC pulse or AC welding waveforms at a controlled waveform phase angle. The systems include a synchronizing controller to synchronize the welding waveforms, and a work point allocation system provides one or more work point values to the welding machines to provide synergic control of the welding according to a user selected system work point value or parameter. The systems and methods further provide for synchronized work point value modulation for the opposite sides of a dual fillet weld. The system and method further provide a high energy heat source that directs intense heat at a portion of the weld joint to improve weld penetration.