Abstract: A feed control method is provided for consumable electrode AC arc welding, in which the welding wire is fed at a predetermined wire feed rate, and a welding voltage applied to an arc is switched in alternation between positive polarity and negative polarity. In the method, a welding current setting signal is generated. The wire is fed at a first feed rate during a period of the positive polarity, whereas the wire is fed at a second feed rate different from the first feed rate during a period of the negative polarity.

Abstract: A universal AC to DC converter may be configured to convert alternating current (AC) to direct current (DC), such as for use in aerospace applications. The disclosure relates to a single universal power electronic converter capable of converting an AC input voltage, such as a line to neutral input voltage of either 115 Vrms or 230 Vrms nominal to 28 V DC.

Abstract: A method for monitoring a spatter generating event during a welding application. The method includes capturing data that corresponds to a welding current of the welding application. The method also includes detecting parameters associated with a short circuit from the captured data. The method includes analyzing the detected parameters to monitor the spatter generating event during the welding application.

Abstract: A laser welding apparatus includes laser generator, arc generator, wire feeder, filler feeder, filler-feeding-abnormality detector, and controller. Controller stops welding immediately upon receiving a filler-feeding-abnormality signal from filler-feeding-abnormality detector. This can stop welding before the formation of a defective weld bead, and can also prevent the breakage of the welding apparatus.

Abstract: A welding system is provided that includes a wearable wire feeder. The wearable wire feeder includes a control unit configured to generate a control signal and a wire drive responsive to the control signal. Another welding system is provided that includes a wearable wire feeder that includes a wire drive, a circuit configured to control a welding parameter, and a battery coupled to the circuit, the wire drive, or a combination thereof. In another embodiment, a welding system is provided that includes a wire drive, a control unit configured to control the wire drive and a gas control configured to control flow of a gas. A method is also provided that includes generating a control signal within a wearable wire feeder and driving a welding wire within the wearable wire feeder in response to the control signal.

Abstract: A welding system includes a welding wire feeder, a welding power supply, and a sensor. The power supply is coupled to the welding wire feeder and configured to produce a welding arc. The sensor is configured to sense a parameter indicative of a size of a welding wire fed through the welding wire feeder. The sensor is configured to send a signal to the power supply, the signal representing the parameter indicative of the size of the welding wire. The power supply is configured to automatically implement at least one of an arc starting parameter or a welding parameter based on the signal.

Abstract: A monitor for determining the operation condition of at least one cable that suffers bending and/or twisting and constitutes an electrical loop and a method thereof are provided. The monitor comprises a test electrical signal generator (5) for generating an identifiable test electrical signal and injecting the test electrical signal into the first point of the at least one cable, a test electrical signal filter (7) adapting to extract the injected test electrical signal from the second point of the at least one cable, and a comparator (8) for comparing a predetermined threshold with the difference between the electrical state of the injected test electrical signal and the extracted test electrical signal and producing a warning signal indicating cable fatigue when the difference exceeds the predetermined threshold.

Abstract: A system and a method are provided for improved run-in control during a start of a welding process. A power circuit generates welding output power. A control circuit in communication with the power circuit controls the output power. The control circuit receives a selection of a wire feed speed setting representing a wire feed speed. The control circuit receives a selection of a run-in setting representing a run-in percentage of the wire feed speed. The control circuit determines an effective run-in percentage that is equal to the run-in percentage plus an extra percentage.

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 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: The invention relates to a method for disconnecting a short circuit (30) during short-arc welding, wherein when a short circuit (30) occurs, a time frame (32) is started, in which a defined current profile is performed to disconnect the short circuit within the time frame (32), and the current is increased if the time frame (32) is exceeded, and a corresponding welding device (1). In order to improve the welding quality, after the specifiable time frame (32) expires during a short circuit (30), said current profile for disconnecting the short circuit (30) is detected and at least one value or parameter in the disconnection of the short circuit (30) is stored or saved, wherein at least one value or parameter in the time frame (32) of the following short circuit (30) is adapted according to the stored value or parameter.

Abstract: A system and method is provided in which a surface tension transfer welding function is employed where the welding waveform switches polarity during welding when a short circuit event is detected.

Abstract: The welder interface described above may increase synergy with the welding system for the user. The welder interface receives input parameters of a desired weld from a user and advises a weld process and weld variables for producing the desired weld. The welder interface may be integral with a component of the welding system, or a separate component that may be coupled with the welding system. The welder interface may utilize data from a look-up table, neural network, welding procedure system, or database to advise the weld process and weld variables. The user may utilize the welder interface to simulate the weld process and the effect of the weld variables on a simulated weld. The user may modify the input parameters prior to producing a weld, and the user may modify the weld variables after reviewing the results of the produced weld for subsequent welding applications.

Abstract: A constant voltage (CV) welding process power supply including a controller that implements a variable minimum current is provided. The controller is configured to periodically compute a running current value during a welding operation. The controller is also configured to periodically compute a minimum current value based on a difference between the running current value and a preset offset value, wherein the preset offset value remains constant throughout the welding operation.

Abstract: A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer.

Abstract: A method and apparatus for welding is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.

Abstract: Methods and systems are provided for using optical interferometry in the context of material modification processes such as surgical laser or welding applications. An imaging optical source that produces imaging light. A feedback controller controls at least one processing parameter of the material modification process based on an interferometry output generated using the imaging light. A method of processing interferograms is provided based on homodyne filtering. A method of generating a record of a material modification process using an interferometry output is provided.

Abstract: As a conventional problem, welding on surface-treated material, such as a zinc-coated steel plate, considerably generates air holes including blowholes and also generates lots of spatters. Present invention provides a method of controlling arc welding performed in a manner that a short-circuit period, in which a short circuit is generated between a welding wire and an object to be welded, and an arc period, in which an arc is generated after release of the short circuit, are repeated alternately. According to the method, welding current is increased from an arc-regeneration-before current to a first welding current at a detection of release of the short circuit such that an increase gradient of the welding current becomes not less than 750 A/msec. This suppresses generation of air holes and spatters in welding work on a surface-treated material, such as a zinc-coated steel plate.

Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: A method and a system to increase heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. A cycle of the electric welding waveform includes a pinch current phase providing an increasing pinch current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and a background current phase providing a background current level. At least one heat-increasing current pulse of the cycle is generated, providing a heat-increasing current level, during the background current phase, where the heat-increasing current level is above the background current level. The cycle of the electric welding waveform with the at least one heat-increasing current pulse may be repeated until the arc welding process is completed.

Abstract: A processing target reforming apparatus includes: a conveying unit that conveys a processing target along a conveyance path; a discharge unit including a plurality of discharge electrodes aligned along the conveyance path, a counter electrode with the conveyance path interposed therebetween, and a power source that applies a voltage waveform to the discharge electrodes; and a control unit that controls the discharge unit such that a phase of the voltage waveform applied to a first discharge electrode of the discharge electrodes at a timing when a certain point of the processing target passes between the first discharge electrode and the counter electrode is shifted with respect to a phase of the voltage waveform applied by the power source to a second discharge electrode of the discharge electrodes at a timing when the certain point of the processing target passes between the second discharge electrode and the counter electrode.

Abstract: A welding apparatus for applying consecutive welding beads during a welding operation includes a welding unit including a torch head and a power circuit. The welding apparatus further includes a first pyrometer and a second pyrometer positioned respectively at a first and second pre-determined distance from a tip portion of the torch head, the first and second pyrometers are configured to respectively generate a first temperature signal and a second temperature signal indicative of temperatures of a portion of successive welds. The welding apparatus further includes a controller configured to receive the first temperature signal and the second temperature signal, determine a difference between the first and second temperature signals, set a predetermined threshold based, at least in part, on the determined difference, and adjust a welding parameter of the power circuit, wherein the adjusted welding parameter is lesser than the predetermined threshold.

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: An arc welding system and methods. The system is capable of monitoring variables during a welding process, according to wave shape states, and weighting the variables accordingly, detecting defects of a weld, diagnosing possible causes of the defects, quantifying overall quality of a weld, obtaining and using data indicative of a good weld, improving production and quality control for an automated welding process, teaching proper welding techniques, identifying cost savings for a welding process, and deriving optimal welding settings to be used as pre-sets for different welding processes or applications.

Abstract: A welding-type power supply includes a controller, bus (that can, but need not be preregulated), and an output converter. The controller has a preregulator control output and an output converter control output. The controller may receive bus feedback indicative of a plurality of bus voltages. A bus voltage balancing module in the converter includes a scaled correction module responsive to the bus feedback signal, and the converter control output is responsive to the bus voltage balancing module. The controller may receive load feedback indicative of a load output, have a bus voltage balancing module that includes a load proportional gain module responsive to the load.

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 power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: An arc-welding method in welding by repeating a short circuit and an arc. When the sign of opening of the short circuit is detected, the welding current is reduced from a first current value at the detection of the sign to a second current value, which is lower than the first current value. When the opening of the short circuit is detected, a pulse current having a peak value higher than the first current value is supplied at a plurality of times in the arc period. This suppresses porosities and spatters when galvanized steel sheets are welded.

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: A method is provided for controlling a neck detection for a welding power supply. The neck detection can be suitably performed even if the welding power supply is combined with another power supply for performing a simultaneous arc welding operation at a plurality of locations of a workpiece.

Abstract: A method and system to weld or join coated workpieces using an arc welding operation and at least one hot wire, resistance heated wire. Each of the arc welding and hot wire operation are directed to the same puddle. However, the arc welding operation is offset out of the joint from the hot wire operation, where the hot wire is directed into the joint.

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: The technology features an apparatus and a method for sensing the length of a lead that connects to a power source to a thermal processing system such as a plasma torch system. Components disposed in the thermal processing system enable the length of the lead to be sensed. In addition, the time for contact starting a thermal processing system enables determination of the length of the lead.

Abstract: A method and apparatus for welding is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.

Abstract: The invention described herein generally pertains to a system and method related to energizing a welding wire based on a location of an electrode at an edge on a workpiece. An edge detector can be configured to identify an edge on the workpiece during a welding operation and a controller can be configured to mange a temperature of a puddle formed by the electrode by adjusting one or more welding parameters. The welding parameters can be, but are not limited to, an energizing of the welding wire, a wire feed speed, a temperature of a high intensity heat source (e.g.

Abstract: A power supply for welding, cutting and similar operations includes one or more power converters that are controlled by PWM signals applied by control circuitry. The signals may be applied for a period greater than 50% duty cycle. The duty cycle may be determined by monitoring power or current draw by a welding or cutting operation load. Where more than one converters is used, each may have the same or different duty cycles, and each may be extended beyond a 50% maximum.

Abstract: An arc welding apparatus includes: a driver for advancing and retreating a welding consumable with respect to a workpiece to generate a short circuit condition and an arc condition; a state detector for detecting respective starts of the short circuit condition and the arc condition based on a voltage between the workpiece and the welding consumable; a time detector for detecting that an elapsed time from the start of the short circuit condition reaches a reference time using a time shorter than an estimated continuation time of the short circuit condition as the reference time; and a power controller for reducing an electric current between the workpiece and the welding consumable corresponding to a state where the elapsed time reaches the reference time and raising the electric current after the start of the arc condition.

Abstract: An arc welding apparatus includes: a welding-condition acquirer configured to acquire a welding condition; a heat-input calculator configured to calculate a required heat input corresponding to the welding condition; a frequency setter configured to set a smaller frequency for a short circuit condition and an arc condition corresponding to an increase in the required heat input; and a driver configured to repeatedly perform a process at the frequency, the process including advancing and retreating a welding consumable with respect to a workpiece to generate the short circuit condition and the arc condition.

Abstract: In a method for controlling pulse arc welding where an arc is created between a wire and a base material, a pulse waveform different from the pulse waveform for steady-state welding is outputted when a predetermined time has passed since short-circuit welding control was started at arc start, and after a sufficiently large melt pool is formed, the pulse waveform for the steady-state welding is outputted. This reduces the generation of spatters after an arc is created and until the arc is stabilized.

Abstract: A plasma cutting or welding system includes a power input. The power input is configured to be coupled to a plurality of multipronged input plugs. Each of the multipronged input plugs corresponds to an input voltage. The power supply also includes a user input device for selecting an operating current. The user input device is subdivided into a plurality of current ranges. Each of the current ranges includes an iconic representation of at least one multipronged input plug.

Abstract: A welding system includes a repositionable temperature sensor. The repositionable temperature sensor is configured to detect temperatures corresponding to a workpiece and to provide temperature data corresponding to the detected temperatures. The welding system also includes a power supply configured to receive the temperature data from the temperature sensor. The power supply is configured to modify control of an output of the power supply based on the detected temperature.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.

Abstract: If a short circuit does not occur during deceleration of a wire feed speed in forward feed of a welding wire before the wire feed speed reaches a predetermined wire feed speed, a cyclic change is stopped and the wire feed speed is constantly controlled at the first feed speed. If a short circuit occurs during forward feed at the first feed speed, deceleration from the first feed speed starts, and the cyclic change is resumed for welding. This achieves uniform weld bead without increasing spatters even if any external disturbance such as change of distance between a tip and base material occurs.

Abstract: A welding power supply and method are provided with a single welding mode in its controller such that the power supply can change from full DCEN output to AC output to a full DCEP output without having to change welding modes.

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

Abstract: An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece. Molten metal droplets are quickly created during negative polarity portions of the weld cycle. Welding controls include integrating a parameter during the negative polarity portions to determine when a desired amount of energy has been generated at the welding wire. This energy is associated with a desired droplet size for consistent droplet transfers to the workpiece.

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

Abstract: A system and method is provided for narrow groove joining of metals. The method includes feeding a wire to a weld joint formed by the metals to be joined and transmitting a welding current through a length of the wire. The method also includes creating a molten puddle in the weld joint with the welding current. The method further includes performing a low heat transfer process on the wire for a predetermined low heat duration to transfer a first portion of the wire to the molten puddle, and performing a high heat transfer process on the wire for a predetermined high heat duration to transfer a second portion of the wire to the molten puddle. The low heat transfer process creates the molten puddle at a root of the weld joint. The high heat transfer process creates an arc that climbs sidewalls of the weld joint and the molten puddle follows the arc up the sidewalls to a top of the weld joint.

Abstract: A welding power supply including power conversion circuitry adapted to receive a primary source of power, to utilize one or more power semiconductor switches to chop the primary source of power, and to convert the chopped power to a welding output is provided. The provided welding power supply includes a pulse width modulated (PWM) digital controller including gate drive circuitry that generates a PWM output signal that controls the switching of the one or more power semiconductor switches. The PWM output signal includes a duty cycle term corrected for one or more sources of error in the welding system.