Abstract: The present invention is directed to a welding-type power source controller that includes a processor configured to control a welding-type power source to produce a variable maximum output that can exceed a rated maximum output based on actual operating conditions, as opposed to standardized maximum rated operating conditions.

Abstract: A number of methods to support process quality and maintenance during control of an industrial process such as welding are provided. The methods provide, among other things: automatic process limit programming based on runtime data; user-initiated process limit programming based on upcoming data; correlate equipment deterioration based on capability measurement; correlate tip dressers/formers to new; detect electrical deterioration; integrate process data with programmed data for a visual aid; and quantify process variation in welding tools (pareto of stddev of the c-factor).

Abstract: A squeezing detection control method is provided for consumable electrode arc welding in which a cycle of arc generation and short-circuiting is repeated between a consumable electrode and a base metal. First, squeezed droplet is detected as a premonitory sign of arc recurrence at the end of the short-circuiting. This detection is based on a fact that a squeeze detection reference value is attained by a differential value of the voltage or resistance between the consumable electrode and the base metal. Then, a welding current supplied to a short-circuit load is rapidly decreased upon detection of the squeezed droplet. Upon recurrence of the arc, the welding current is increased. This arc recurrence is detected by a fact that the differential value attains an arc recurrence reference value which is greater than the squeeze detection reference value.

Abstract: A method for reducing spatter in the short-circuit transfer gas shielded arc welding is disclosed. In this method, the resistance changing rate or the impedance changing rate of the welding circuit loop is detected for estimating the diameter of the short-circuit liquid bridge. When the diameter of the short-circuit liquid bridge shrinks to the preset value, the short-circuit bridge current is bypassed or shunted by the current closed loop feedback bypass control, and the current is decreased to a very low level rapidly and maintained this level until the bridge is broken, which results in a gentle and smooth drop transfer in a low current level condition, so as to avoid the mass spatter. Furthermore, a system for performing the method has also been disclosed.

Abstract: A device to control operation of a power source for an electric arc welder comprising an oscillator for inducing a high frequency voltage into a series circuit including the welding gap, a detector tuned to the high frequency for sensing the level of current in the series circuit at the high frequency and an output circuit to create a start signal when the received signal level exceeds a given value representing a resistance in said gap below a given amount.

Abstract: A welding control system to monitor the energy consumption of a plurality of welders. The welding control system controls the operation of one or more welders based upon the energy information received from one or more energy monitoring devices.

Abstract: An electric arc welder with a waveform generator controlled to create a welding process involving current flow between an electrode and a workpiece wherein the welding process comprises a succession of pulse waveforms, each having a current ramp up portion, a peak current portion, a current ramp down portion and a background current portion, a voltage sensing circuit to sense a short circuit between the electrode and the workpiece and a reset circuit to reset the waveform generator upon sensing of a short circuit. The preferred electrode is a solid wire which may be in the form of a metal cored wire.

Abstract: The invention relates to earth connections to workpieces particularly a workpiece to which an arc is to be struck, and more particularly to a workpiece that is underwater. It is of considerable importance that a workpiece is properly connected to earth, and that the impedance of the connection is not such as will elevate dangerously the voltage on the workpiece. The objective of the invention is to solve this problem, an objective met by an earth connection for workplaces that comprises a loop in the connection of the workpiece to earth, the loop being connected at each end to and being completed by the workpiece, and there being a sensor means to sense current flowing in the loop above a predetermined level.

Abstract: A generator for unitary power factor arc welders, comprising a current transformer that supplies, at a secondary winding thereof, a welding arc and is in turn supplied, at a primary winding thereof, by an input leveling and rectifying unit, between the rectifier unit and the transformer being interposed an electronic circuit with two electronic switches that provide a half-bridge structure that performs DC/DC conversion by way of the combination of the transformer and of a rectifier stage connected to the secondary winding of the transformer, and a leveling inductor, the circuit having the combination of resonant capacitive and inductive components arranged on the side of the primary winding of the transformer, the components charging the bank of capacitors arranged downstream of the electronic switches, furthermore keeping the voltage across it constant.

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: An input rectifier of a power supply apparatus rectifies a selected one of two, higher and lower AC voltages applied to it. First and second inverters are connected in the output of the input rectifier. A high-frequency transformer is connected to the output of each of the first and second inverters. An output rectifier is connected to the output of each of the high-frequency transformers. When the higher one of the two AC input voltages is applied to the input rectifier, a switching circuit connects the first and second inverters in series between output terminals of the input rectifier. When the lower AC voltage is applied to the input rectifier, the switching circuit connects the first and second inverters in parallel between the output terminals of the input rectifier. When the first and second inverters are connected in series between the output terminals of the input rectifier, a voltage balancing control unit operates to suppress imbalance between input voltages to the first and second inverters.

Abstract: The invention relates a method for gas-shielded metal-arc welding during the re-strike during the welding process. It is object of the invention to provide a gas-shielded metal-arc welding method to permit as low an energy intake as possible in the short-circuit phase for the arc welding. According to the invention, this object is solved by a method, characterized in that at the beginning of a short-circuit, a control is activated and remains active for the duration of the short-circuit, which increases an energy intake (phase A) when a characteristic threshold value S1 is fallen short of, and terminates the energy intake when a threshold value S2 is reached, and than lowers the energy intake (phase B).

Abstract: A solid-state contactor for an arc welder is provided. The contactor includes a processor assembly configured to generate a logical signal. The processor assembly includes an output and a processor. The processor is configured to generate the logical signal at the output. A switch is configured to conduct electrical current from a power source to a wire conductor in response to the logical signal at the output.

Abstract: An electric arc GMAW welder is provided, which welder includes a high speed switching power supply with a controller for creating a first or second weld process across the gap between a workpiece and a welding wire advanced toward the workpiece. The first process uses a first current waveform and the second process uses a second current waveform. A circuit is provided for shifting between the first and second weld processes. The shifting circuit includes a counter for counting the waveforms in the first and second processes and a circuit to shift from the process being processed to the other weld process when the waveform count of the weld process being processed reaches a preselected number for such weld process.

Abstract: An operating system is provided for an electric arc welder including a high switching speed inverter power source for creating an arc voltage and arc current between an electrode and a workpiece. This operating system regulating the arc voltage to provide a voltage with a slope by using an error circuit to create an error output and having a first input with a signal representing the set voltage and a second input representing the sum of the actual arc voltage and the actual arc current multiplied by a slope constant. A DSP program reduces the error output by adjusting the voltage output of the inverter power source to change the actual arc voltage. The slope constant is in the range of 0–10%.

Abstract: The present invention is directed to a MIG welding machine having a 115 volt inverter. Incorporation of the 115 volt inverter into the MIG welding power source reduces the weight of the power source thereby increasing its portability. The power source may include a power factor correction circuit to provide a near-unity power factor such that output power of the inverter is more efficiently provided. Additionally, the 115 volt inverter is constructed such that for short periods of time, the inverter may output power at a level that exceeds its power rating.

Abstract: A method and apparatus for providing a welding current is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding. The welding current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and an auxiliary power controller that can receive a range of input voltages and provide a control power signal to the controller.

Abstract: The invention relates to a method of linking several current sources, in particular several welding devices (1; 27; 28), plasma current sources or similar. Operating individually and independently of one another, a process control and/or regulating system (4; 31; 32) in every welding device (1; 27; 28) transmits desired values to a voltage-to-current controller of a power component (3; 29; 30). The power component (3; 29; 30) supplies a consumer connected to output jacks (38, 39; 40, 41; 42, 43) with power on the basis of the desired values.

Abstract: The invention describes a welding apparatus (1), which has a current source (2) for supplying electrical power to at least one electrode at a welding torch (10) and a control system (4) co-operating with the current source (2), linked to an input device (22) for entering settings for different welding parameters, several sensing means being provided for detecting various actual values of a welding process. At least one measuring device or system for sensing mechanical motion, in particular a welding wire displacement and/or a welding torch displacement or similar, is provided, which detects a surface structure of an object.

Abstract: A method and apparatus for short circuit welding includes providing welding power suitable for short circuit welding, sensing the stick out length, and adjusting the welding speed, such as wire feed speed or travel speed, adjusting a welding parameter, or adjusting thee gas mixture in response thereto. Stick out is preferably determined by measuring a welding parameter, and performing an FFT on the parameter, and then calculating stick out, in one embodiment. Stick out can be either CTTWD or CPTPD. The system can determine when a short is about to clear by calculating a value Vc defined by Vc=d/dt(kl*dp/dt), and comparing Vc to a Vthreshhold, which varies in response to welding cycle history.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal to drive the output current. The command signal is comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command. Arc voltage feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by an instantaneous, or short-by-short, adjustment of the current command. A function of the time derivative of arc power, less the time derivative of arc current, is used to detect, in real time, when the short is about to clear. A stop algorithm is employed that monitors the arc on a short-by-short basis. When the process is ending a very low current level is provided to avoid forming a ball.

Abstract: The present invention is directed to a welding-type power source that includes a power source housing and an engine arranged in the power source housing to supply electrical power. An energy storage device is included that is in rechargeable association with the internal combustion engine and arranged to provide welding-type power for at least a given period.

Abstract: A method of protecting data stored in a memory of a welding controller provided with an EEPROM as a storage element capable of storing welding control data in a welding controller, thereby enhancing reliable protection of data stored in the EEPROM. The method of protecting data stored in a memory of a welding controller comprises the steps of providing the EEPROM having write validity control function means in the controller, using the EEPROM as a storage element for storing welding control data therein, writing the welding control data into the EEPROM and storing the same in the EEPROM, reading the welding control data from the EEPROM when the welding controller is used, and rendering the EEPROM transitive from a write disable state to a write enable state by the write validity control function when the welding control data is changed.

Abstract: A method and apparatus for controlled short circuit welding includes providing welding-type power and controlling the welding-type power to be controlled short circuit power. A user selectable heat control input is received and the heat content of a drop, each drop, or a plurality of drops is adjusted in response thereto.

Abstract: An electric arc welder for performing a given weld process with a selected A.C. pulse current waveform performed between an electrode and a workpiece, where the current waveform includes a positive segment and a negative segment, with at least one segment including a peak current and background current. The welder comprises: a power source with a controller having a digital processor including a program to calculate the real time power factor of the weld current and weld voltage where the program includes an algorithm to calculate the rms weld voltage, the rms weld current and the average power of said power source; a circuit to multiply the rms current by the rms voltage to produce an rms power level; a circuit to divide the average power by the rms power to create a value representing the actual real time power factor of said power source; and, a circuit to adjust said background current to maintain said power factor at a given level, which is manually adjusted to set the heat of the weld.

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 present invention relates to an arc welding method in which generation of spatters can be suppressed while the use quantity of gas to be supplied to a welding portion can be decreased. A welding wire 8 is brought into contact with a work W while applying a voltage between the welding wire 8 and the work W, so that the end of the welding wire 8 is caused to be fixingly welded to the work W. At this time, an electric resistance between the welding wire 8 and the work W is continuously obtained during the contact between the welding wire 8 and the work W, and thus, a minimum of the electric resistance is detected. When the current is temporarily reduced after the detection of the minimum of the electric resistance, the tip of the welding wire 8 hardly bursts, thus suppressing the expelling of molten particles, which may cause spatters, from the welding wire 8. The minimum value is also used for the torch-to-workpiece distance control.

Abstract: A robotic apparatus and system adapted to communicate with a wireless sensor. The apparatus may be either physical or virtual in nature and is adapted to communicate physical movements with a wireless sensor. Data received from the sensor and/or robotic apparatus may be reviewed in a real-time mode, or may be saved for review at a later time. In addition, the apparatus may be controlled through an operator that is in local or remote communication with the apparatus. The robotic system may include pre-programmed interactive platforms for enabling communication between a user and the apparatus in a dynamic mode. In addition, the system may allow an operator to program a game/story for use as an interactive platform. Accordingly, the apparatus and system provides a platform for rehabilitative exercise of a patient as well as an entertainment device.

Abstract: A method and apparatus for welding that includes a power source and a wire feeder is disclosed. One or more sensors sense one or more welding conditions before the weld is initiated. A set up circuit is coupled to sensor, the power source, and the wire feeder. The set up circuit automatically sets up the welding machine in response to what the sensor senses. The sensor may be a wire sensor, including a diameter sensor and a material sensor, a gas sensor (if a source of gas is included) such as a cyclic voltametry gas microsensor, a workpiece thickness sensor such as a strain gauge or displacement sensor. Alternatively the sensor includes a bar code reader that reads a code on, for example, the spool of wire, an analog proximity detector, a plurality of proximity detectors, and a displacement sensor.

Abstract: A method and apparatus for providing a welding current is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding. The welding current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and an auxiliary power controller that can receive a range of input voltages and provide a control power signal to the controller.

Abstract: The invention describes a method of controlling a welding current source (2) having a resonant circuit (27), whereby a bridge circuit (28) is controlled by a control system (4). A consumer, in particular a welding process, is supplied with energy via the bridge circuit (28) from a power source (29). In order to control the individual switching elements (32-35) of the bridge circuit (28), fixed pre-set control states S1 to S6 are stored and, during normal operation, the bridge circuit (28) is controlled on the basis of the control states S1 to S4 one after the other. If a change in resistance occurs at the consumer, the control system (4) switches to a special operating mode at the resonance frequency of the resonant circuit (27) and the bridge circuit (28) is controlled on the basis of the stored control states in order to run the special operating mode.

Abstract: The present invention relates to an arc welding method in which generation of spatters can be suppressed while the use quantity of gas to be supplied to a welding portion can be decreased. A welding wire 8 is brought into contact with a work W while applying a voltage between the welding wire 8 and the work W, so that the end of the welding wire 8 is caused to be fixingly welded to the work W. At this time, an electric resistance between the welding wire 8 and the work W is continuously obtained during the contact between the welding wire 8 and the work W, and thus, a minimum of the electric resistance is detected. When the current is temporarily reduced after the detection of the minimum of the electric resistance, the tip of the welding wire 8 hardly bursts, thus suppressing the expelling of molten particles, which may cause spatters, from the welding wire 8. The minimum value is also used for the torch-to-workpiece distance control.

Abstract: A power supply for arc welding includes switching elements PTR, NTR for switching the polarity of the direct voltage from a power circuit PMC. The element PTR is connected in parallel to a series unit of a switching element TR1 and a resistor R1. Likewise, the element NTR is connected in parallel to a series unit of a switching element R2 and a resistor R2. A necking determination circuit ND determines whether a constriction occurs at the molten bridging portion between the welding wire and the base material. When the constriction occurs during the “electrode positive” mode, the switching element PTR is turned off, while the switching element TR1 is brought into the conduction state. When the constriction occurs during the “electrode negative” mode, the switching element NTR is turned off, while the switching element TR2 is brought into the conduction state.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal to drive the output current. The command signal is comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command. Arc voltage feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by an instantaneous, or short-by-short, adjustment of the current command. A function of the time derivative of arc power, less the time derivative of arc current, is used to detect, in real time, when the short is about to clear. A stop algorithm is employed that monitors the arc on a short-by-short basis. When the process is ending a very low current level is provided to avoid forming a ball.

Abstract: A method and apparatus for controlled short circuit welding includes providing welding-type power and controlling the welding-type power to be controlled short circuit power. A user selectable heat control input is received and the heat content of a drop, each drop, or a plurality of drops is adjusted in response thereto.

Abstract: A method and apparatus for welding is disclosed. It includes a source of power and a controller. An output feedback circuit provides feedback to the controller. The controller includes a comparator that compares the fedback signal to a threshold and/or detects a short on the output. A standby/welding control is responsive to the comparator. Also, an arc end control may be provided that terminates the arc in response to detecting an increase in arc length.

Abstract: A method and apparatus for providing a welding current is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding. The welding current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and an auxiliary power controller that can receive a range of input voltages and provide a control power signal to the controller.

Abstract: A short circuit arc welding system is disclosed. The control scheme uses a current command signal to drive the output current. The command signal is comprised of a long-term current command that sets the long-term current command level and a real-time or short-by-short current command. Arc voltage feedback is used to determine if the desired arc length is present and to adjust the long-term command. The short-by-short current command is derived from real-time arc current feedback and is used to control the burn-off rate by an instantaneous, or short-by-short, adjustment of the current command. A function of the time derivative of arc power, less the time derivative of arc current, is used to detect, in real time, when the short is about to clear. A stop algorithm is employed that monitors the arc on a short-by-short basis. When the process is ending a very low current level is provided to avoid forming a ball.

Abstract: A method and apparatus for short circuit welding includes providing welding power suitable for short circuit welding, sensing the stick out length, and adjusting the welding speed, such as wire feed speed or travel speed, adjusting a welding parameter, or adjusting thee gas mixture in response thereto. Stick out is preferably determined by measuring a welding parameter, and perforrming an FFT on the parameter, and then calculating stick out, in one embodiment. Stick out can be either CTTWD or CPTPD. The system can determine when a short is about to clear by calculating a value Vc defined by Vc=d/dt(kl*dp/dt), and comparing Vcto a Vthreshhold, which varies in response to welding cycle history.

Abstract: A system and method for controlling a weld-current in an arc welding apparatus involves programming of a waveform generator to supply a control signal to a weld-current power supply, the control signal being derived from a reference waveform consisting of selected segments having fixed or predetermined amplitudes and variable durations. The reference waveform may be dynamically adjusted in response to changes in welding conditions by feeding the output of an arc current and/or voltage detector back to the waveform generator and varying the duration of selected predetermined amplitude segments.

Abstract: A method and apparatus for providing welding-type power includes a power circuit, a temperature sense circuit, a switch feedback circuit, and a controller. They cooperate to provide thermal management based on a switch parameter, such as current, in addition to a sensed temperature.

Abstract: A method and apparatus for welding includes one or more of a welding type power source, a feedback circuit, a wire feeder and a controller. The controller preferably has an eta control circuit responsive to the feedback. It also has a control loop having a response time responsive to the eta output. The controller detects whether or not the process is a fast-tack process, and controls the supply of power according to a first control scheme is the process is a fast-tack process, and according to a second control scheme if the process is not a fast-tack process. The controller sets the run-in wire feed speed as a percentage of weld wire feed speed, preferably obtaining the percentage from the weld wire feed speed potentiometer at start up. The controller enters a calibration mode at start up if a calibration pendant is attached and on. In the calibration mode calibration receiving values from the front panel potentiometers.

Abstract: The invention relates a method for gas-shielded metal-arc welding during the re-strike during the welding process. It is object of the invention to provide a gas-shielded metal-arc welding method to permit as low an energy intake as possible in the short-circuit phase for the arc welding. According to the invention, this object is solved by a method, characterized in that at the beginning of a short-circuit, a control is activated and remains active for the duration of the short-circuit, which increases an energy intake (phase A) when a characteristic threshold value S1 is fallen short of, and terminates the energy intake when a threshold value S2 is reached, and than lowers the energy intake (phase B).

Abstract: The present invention is directed to a method and apparatus of controlling the welding output of a welding power source by incorporating an open condition detect circuit. An output feedback circuit provides feedback to a controller such that the controller may regulate the output of the welding source of power. As such, the controller prevents a welding output until an open condition followed by a short condition at the welding area is detected.

Abstract: The present invention is directed to a method and apparatus of controlling the output of a welding power source with a fused electrode detection circuit. The present invention incorporates a fused electrode detection circuit to regulate the output of the welding system power source. By providing feedback as to when the electrode begins to stick in the weld, the output of the power source may be regulated to allow easy diffusing of the electrode. That is, by reducing the output of the power source upon detection of a fused electrode condition, a user or technician can remove or unstick the electrode from the weld without having to shut down the power source or without forcefully removing it while power is on and creating large, damaging arcs. By limiting the output of the power source until the electrode is “unstuck”, the present invention reduces the likelihood of damaged electrodes, electrode holders, and welds.

Abstract: A control method for arc welding wherein position control of an electrode or a torch is performed while adjusting welding conditions on the basis of optical information obtained from arc light generated during an arc welding process. Illuminance, which forms the optical information obtained from the arc light, has a certain mutual relationship with the arc length or the torch height, so that the weld control is accomplished based on the illuminance. The control method includes a step of comparing illuminance with reference information based on the mutual relationship, and a step of adjusting the welding conditions on the basis of a result of comparison.

Abstract: The present invention is directed to a method and apparatus of controlling the output of a welding power source with a fused electrode detection circuit. The present invention incorporates a fused electrode detection circuit to regulate the output of the welding system power source. By providing feedback as to when the electrode begins to stick in the weld, the output of the power source may be regulated to allow easy diffusing of the electrode. That is, by reducing the output of the power source upon detection of a fused electrode condition, a user or technician can remove or unstick the electrode from the weld without having to shut down the power source or without forcefully removing it while power is on and creating large, damaging arcs. By limiting the output of the power source until the electrode is “unstuck”, the present invention reduces the likelihood of damaged electrodes, electrode holders, and welds.

Abstract: A method and apparatus for providing welding-type power includes a power circuit, a temperature sense circuit, a switch feedback circuit, and a controller. They cooperate to provide thermal management based on a switch parameter, such as current, in addition to a sensed temperature.

Abstract: A solid-state contactor for an arc welder is provided. The contactor includes a processor assembly configured to generate a logical signal. The processor assembly includes an output and a processor. The processor is configured to generate the logical signal at the output. A switch is configured to conduct electrical current from a power source to a wire conductor in response to the logical signal at the output.

Abstract: A power supply for arc welding includes switching elements PTR, NTR for switching the polarity of the direct voltage from a power circuit PMC. The element PTR is connected in parallel to a series unit of a switching element TR1 and a resistor R1. Likewise, the element NTR is connected in parallel to a series unit of a switching element R2 and a resistor R2. A necking determination circuit ND determines whether a constriction occurs at the molten bridging portion between the welding wire and the base material. When the constriction occurs during the “electrode positive” mode, the switching element PTR is turned off, while the switching element TR1 is brought into the conduction state. When the constriction occurs during the “electrode negative” mode, the switching element NTR is turned off, while the switching element TR2 is brought into the conduction state.