Abstract: Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.

Abstract: Welding wire preheating systems and methods are disclosed. An example welding method includes: receiving a signal indicative of initiation of welding process; prior to initiating a welding arc based on the received signal, controlling voltage or current applied to a welding electrode to preheat the electrode to a temperature above an ambient temperature but below a melting point of the welding electrode; monitoring feedback voltage to determine a termination of preheating; and terminating preheating prior to initiating the welding arc in accordance with a welding protocol.

Abstract: An example welding user interface system includes: a user interface configured to receive a plurality of control inputs indicative of a plurality of weld specifications, wherein the plurality of weld specifications comprise two or more physical attributes of a weld, the physical attributes comprising two or more of a workpiece thickness, a joint type, a workpiece material, a fillet size, a penetration depth, a penetration profile, a bead width, a wire type, a wire feed speed, or a gas type; and a processor configured to convert the weld specifications from the plurality of control inputs into electrical parameters of a welding power source, and to control an output welding power of the welding power source based at least in part on the electrical parameters.

Abstract: Methods and apparatus to communicate via a weld cable are disclosed. An example weld circuit communications device includes a receiver circuit, a processor, and a local communications adapter. The receiver circuit to receive a communication via a weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit, the communication including weld voltage feedback information measured at a device remote from a power supply and remote from the weld circuit communications device while the current is flowing through the weld circuit. The processor generates power supply control information based on the weld voltage feedback information. The local communications adapter transmits the power supply control information to control welding-type power output by a power converter to regulate a weld voltage to a weld voltage setpoint.

Abstract: A welding system is provided that includes an engine, a compressor coupled to the engine, and a regulator coupled to the compressor and located on a control panel. Another welding system is provided that includes an engine, a compressor coupled to the engine and a monitor circuit configured to monitor the duration of operation of the compressor by monitoring engagement of the clutch. A pressure gauge configured to be coupled to a compressor is also provided.

Abstract: The purpose of the present invention is to reduce the amount of sputtering in a welding method wherein a welding wire feed rate is alternately switched between a forward feed period and a reverse feed period. Provided is an arc welding control method that switches a feed rate Fw for welding wire alternately between a forward feed period and a reverse feed period, repeats a short period and an arc period, and electrifies with a welding current Iw switched to a small current value in the latter half of the arc period, wherein a basic voltage setting value is set according to an average feed rate setting value, the error amplitude value for a voltage setting value and the basic voltage setting value is calculated, and the timing (current reduction time Td) for switching the welding current Iw to the small current value is varied on the basis of the average feed rate setting value and the error amplitude value.

Abstract: A polarity-selectable high voltage direct current power supply including a first drive assembly that transforms a first low voltage DC input into a first medium voltage alternating current output; a first HV output assembly that transforms the first LV AC output into a first HV DC output, wherein the first HV output assembly defines a first input stage; a polarity selector coupled between the second output junction of the first drive assembly and the first and second input stages of the first HV output assembly, the polarity selector operable between a first configuration and a second configuration; wherein in the first configuration the first HV DC output has a positive polarity; and wherein in the second configuration the first HV DC output has a negative polarity.

Abstract: A weld production knowledge system for processing welding data collected from one of a plurality of welding systems, the weld production knowledge system comprising a communication interface communicatively coupled with a plurality of welding systems situated at one or more physical locations. The communication interface may be configured to receive, from one of said plurality of welding systems, welding data associated with a weld. The weld production knowledge system may comprise an analytics computing platform operatively coupled with the communication interface and a weld data store. The weld data store employs a dataset comprising (1) welding process data associated with said one or more physical locations, and/or (2) weld quality data associated with said one or more physical locations. The analytics computing platform may employ a weld production knowledge machine learning algorithm to analyze the welding data vis-à-vis the weld data store to identify a defect in said weld.

Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding torch. The power is provided in accordance with an electrode negative pulse welding regime that includes a cyclic peak, followed by a stabilization phase, then a return to a background level. The stabilization phase has a generally parabolic current shape, and is performed in a current-closed loop manner until a transition point. Resulting weld performance is improved, with a globular-like transfer mode, reduced shorts and enhanced arc stability.

Abstract: A method of operating a welding system includes supplying a weld current and a weld voltage to an electrode via a plurality of pulse periods, where each pulse period of the plurality of pulse periods includes a background phase and a peak phase. The method also includes detecting the occurrence of an anomalous cathode event during the background phase of a first pulse period of the plurality of pulse periods based at least in part on when a voltage value of the weld voltage is greater than a detect voltage. The method also includes controlling the weld current to a desired current during a portion of the anomalous cathode event. The portion includes an interval of the background phase of the first pulse period, and the weld current is controlled independent of the weld voltage during the portion of the anomalous cathode event.

Abstract: Welding wire preheating systems and methods are disclosed. An example welding method includes: receiving a signal indicative of initiation of welding process; prior to initiating a welding arc based on the received signal, controlling voltage or current applied to a welding electrode to preheat the electrode to a temperature above an ambient temperature but below a melting point of the welding electrode; monitoring feedback voltage to determine a termination of preheating; and terminating preheating prior to initiating the welding arc in accordance with a welding protocol.

Abstract: Present embodiments include a system that includes a welding tool configured to receive a welding wire from a wire feeder, to receive welding power from a power source, and to supply the welding wire to a workpiece during a welding process. The system also includes a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece. The structural component is external to the wire feeder and the power source. The system further comprises control circuitry configured to control the welding power based on feedback relating to the welding process.

Abstract: A welding-type system and method for operating a welding-type system is disclosed. The system includes a switched power delivery circuit connected to deliver power to output terminals and an open-circuit voltage (OCV) control circuit configured to adjust an operational state of the switched power delivery circuit. A controller is included that is configured to monitor the output terminals to identify an open circuit condition and selectively engage the OCV control circuit to adjust the operational state of the switched power delivery circuit to reduce a voltage of the output power delivered to the output terminals during the open circuit condition.

Abstract: Methods and apparatus to communicate via a weld cable are disclosed. An example weld circuit communications device includes a receiver circuit, a processor, and a local communications adapter. The receiver circuit to receive a communication via a weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit, the communication including weld voltage feedback information measured at a device remote from a power supply and remote from the weld circuit communications device while the current is flowing through the weld circuit. The processor generates power supply control information based on the weld voltage feedback information. The local communications adapter transmits the power supply control information to control welding-type power output by a power converter to regulate a weld voltage to a weld voltage setpoint.

Abstract: A method and apparatus for controlling arc/short between a wire and a work piece is described. A current path parallel to the wire/work is provided. The voltage drop across the parallel path can be preset, to limit the wire/work voltage, or it can be controlled to a desired level. The control can be in response to feedback.

Abstract: There is provided an arc welding control method. As to a feeding rate of a welding wire, a forward feeding period and a reverse feeding period are alternated cyclically to generate short-circuiting periods and arc periods. When a constriction of a droplet formed at the welding wire is detected during the short-circuiting period, a welding current is reduced to shift to the arc period. Sensitivity of the detection of constriction is changed according to a waveform parameter of the feeding rate.

Abstract: A satellite electric propulsion power supply unit comprises: an internal source of electrical power; an external input adapted to receive an electrical power supply from an external source of electrical power; a first external output and a second external output adapted to deliver as output, respectively, a first electrical power supply and a second electrical power supply; a first selector element and a second selector element such that: the first selector element is equipped with a first internal input connected to the internal source and with two outputs: the first external output and an internal output connected to a second internal input of the second selector element; and the second selector element is equipped with an output corresponding to the second external output and with two inputs: the external input and the second internal input.

Abstract: A system and method is provided for monitoring and displaying real time information regarding the inductance of the welding circuit, such that a user can monitor the performance of a power supply to determine if the system inductance is adversely affecting the operation of the power supply, and where the system can change the output signal based on the detected system inductance.

Abstract: Among other things, a distribution transformer and a technique for regulating voltage are provided for herein. The distribution transformer comprises at least three windings and at least two ferromagnetic cores. The distribution transformer may also comprise a power electronic AC-AC converter operable to maintain the input voltage and current of the distribution transformer substantially in phase and/or to reduce fluctuation in the output voltage of the distribution transformer in the event of an increase or decrease in the input voltage, for example.

Abstract: An engine-driven welder/generator is controlled by an integrated controller that is coupled to both the engine and to the welder/generator. The controller receives input signals for operational parameters of the engine, and additional signals indicative of electrical output by the welder/generator. Operation of the engine and welder/generator may thus be coordinated. The controller may control speed, timing, fuel injection, and so forth of the engine, and output of the welder/generator, such as by control of input to a field coil.

Abstract: Systems and methods providing low current regulation for AC arc welding processes to regulate arc welding performance. In arc welding power source embodiments, configurations of bridge and arc regulation circuits allow for the directional switching of the welding output current through the welding output circuit path and induce a voltage between the electrode and the workpiece of the welding output circuit path that is sufficient to re-ignite the arc during polarity transition of the output current. The arc regulation circuit provides a high inductance level for storing energy, in both polarities, which induces the voltage level for re-igniting the arc during the zero crossing of the output current and provides low end stabilization of arc current.

Abstract: The power conversion device includes a power-supply shunt resistance provided between an inverter and the negative-voltage side of a DC power supply, respective-phase lower-arm shunt resistances provided between the power-supply shunt resistance and respective-phase lower-arm switching elements, a first overcurrent detection unit performing overcurrent detection on a current that flows through the power-supply shunt resistance on the basis of a power-supply shunt-resistance voltage, and a second overcurrent detection unit performing overcurrent detection on each current that flows through the respective-phase lower-arm shunt resistances on the basis of respective-phase lower-arm voltages, wherein overcurrent detection is performed on each phase current using either one of the overcurrent detection result of the first overcurrent detection unit and the overcurrent detection result of the second overcurrent detection unit.

Abstract: A welder power supply and welding method are provided which welds in a DCEN state, but when a short circuit is detected the current waveform switches to an EP state and the short circuit is cleared while the electrode has a positive polarity.

Abstract: Methods, controllers, and power sources for controlling weld states of a MIG welding machine having a 115 volt inverter are provided. The regulation of a power source may include determining a command current signal based on a maximum allowable voltage error determined from the output condition at the weld. The signal may be provided to a controller that regulates the output of the 115 volt inverter. A MIG welding power source may include the 115 volt inverter and a processor that determines a maximum allowable voltage offset from a voltage feedback signal and a voltage level. The processor may provide a signal based on a determined instantaneous command current to regulate the 115 volt inverter.

Abstract: The detection device comprises an electrical power reserve, a voltage regulator configured to regulate the voltage supplied by the electrical power reserve, at least one capacitor charged by the voltage regulator, a detection circuit powered by the capacitor and a switch. The switch is configured to deactivate the regulator when the capacitor's charge is greater than a predefined value, such that the detection circuit is then only supplied with electricity by each said capacitor. The switch can be configured to open the circuit comprising the power reserve upstream of the regulator, and the switch comprises a means of comparing the electrical charge of each capacitor with a predefined value and/or the switch comprises a transistor.

Abstract: In the output control method for a consumable electrode arc welding power source, entire application range of an welding current is segmentalized into a plurality of current zones, a norm welding voltage value is set for each of the current zones, a welding current and a welding voltage are detected at each of minute cycles, the current zone which corresponds to a detected value of the welding current is selected, a fluctuation range is calculated with the norm welding voltage value of the selected current zone as a center value, a welding voltage limit value is calculated while the welding voltage detected value is limited to within the fluctuation range, and the output of the welding power source is controlled based on this welding voltage limit value.

Abstract: Embodiments of a welding power supply include a housing and a diesel engine disposed in the housing and adapted to output a first power output curve and a second power output curve substantially higher than the first power output curve. The welding power supply also includes a controller coupled to the diesel engine and adapted to control the diesel engine to operate along the first power output curve during a low power operation and to control the diesel engine to operate along the second power output curve during a high power operation.

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 method of controlling a welding system includes controlling a weld current supplied to an electrode at a current ramp rate and determining an arc length based at least in part on the controlled weld current and a changing arc voltage. The arc length includes a distance between the electrode and a workpiece, and the arc voltage includes a voltage between the electrode and the workpiece.

Abstract: An arc welding method relates to consumable electrode arc welding in which a welding wire feeding rate suitable for a welding current is determined as an average feeding rate, and the short circuit state and the arc generation state are alternately generated by changing the wire feeding periodically and repeatedly between the forward feeding and the reverse feeding. The method offers arc welding with the average feeding rate according to a welding current, a predetermined frequency, and a predetermined velocity amplitude. In the method, at least any one of the frequency and the velocity amplitude is set to a value suitable for the welding current.

Abstract: One embodiment of the present invention relates to a system for buried-arc welding with thru-the-arc seam tracking. Another embodiment of the present invention relates to a method for buried-arc welding with thru-the-arc seam tracking.

Abstract: A method of operating a welding system includes supplying a weld current and a weld voltage to an electrode via a plurality of pulse periods, where each pulse period of the plurality of pulse periods includes a background phase and a peak phase. The method also includes detecting the occurrence of an anomalous cathode event during the background phase of a first pulse period of the plurality of pulse periods based at least in part on when a voltage value of the weld voltage is greater than a detect voltage. The method also includes controlling the weld current to a desired current during a portion of the anomalous cathode event. The portion includes an interval of the background phase of the first pulse period, and the weld current is controlled independent of the weld voltage during the portion of the anomalous cathode event.

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 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: 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 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: A welding system including a welding power source including power conversion circuitry adapted to receive primary power and to convert the primary power to a weld power output for use in a welding operation and a controller communicatively coupled to the welding power source are provided. The controller is adapted to determine a statistical signature of at least one parameter of a welding process and to utilize the statistical signature to determine at least one of an electrode type, an electrode diameter, and a shielding gas type during the welding operation.

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: In a welding system, a preheating process is carried out prior to initiation of a welding arc, such as upon depression of a trigger or switch on a welding torch. The preheating process involves generation and application of desired currents and voltages to a welding electrode from a power supply. Preheating is continued until the welding electrode reaches a desired temperature or resistance, which may be determined by reference to an increasing voltage, a decreasing current, a peaked and declining voltage, resistance and/or power measurements, and so forth. Following preheating, a desired welding process may begin with initiation of the welding arc.

Abstract: Methods and devices for controlling a welding power source based on a primary supply voltage level are provided. One method may include sensing activation of the welding power source and sensing a primary supply voltage established on a control transformer of the welding power source. The method may also include establishing a substantial current draw from a primary power supply that exceeds a predefined current threshold when the sensed primary supply voltage exceeds a predefined voltage threshold. The substantial current draw may be adapted to trip a circuit breaker of the welding power source to disallow current through the welding power source when the sensed primary supply voltage exceeds the predefined voltage threshold.

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: A welding system including a welding power source including power conversion circuitry adapted to receive primary power and to convert the primary power to a weld power output for use in a welding operation and a controller communicatively coupled to the welding power source are provided. The controller is adapted to determine a statistical signature of at least one parameter of a welding process and to utilize the statistical signature to determine at least one of an electrode type, an electrode diameter, and a shielding gas type during the welding operation.

Abstract: A superimposed voltage waveform with a predetermined cycle and amplitude is superimposed on a commanded voltage waveform for a second predetermined time after a first predetermined time elapses within an arcing period in which an arc is produced. The predetermined cycle of the superimposed voltage waveform is shorter than a short-circuit cycle and longer than a control cycle of a welding power supply unit. This suppresses a growth of a weld droplet by being pushed up toward a consumable electrode and suppresses an excessive growth of the droplet over an entire range from a low current range, characterized by frequent short-circuits, to a medium to high current range where short-circuits are less frequent. The droplet is also smoothly transferred to the weld pool in addition to preventing excessive droplet growth. This reduces the generation of spatter, giving a flatter bead appearance.

Abstract: A shielded metal arc welding machine having a characteristic with a constant current output characteristic and a drooping output characteristic properly combined is provided. A shielded metal arc welding machine having a constant current output characteristic, characterized by having a desired drooping output characteristic, which has an optional drooping degree with a point at which a characteristic line of said constant current output characteristic intersects a welding load characteristic line L as a base point, and replaces said constant current output characteristic.

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 electric welding machine having an auxiliary power output, and a method for controlling the auxiliary power output on a welding machine is provided. In one embodiment, the system includes a main transformer having a first secondary winding in circuit communication with a welder power output and a second secondary winding in circuit communication with an auxiliary power supply having an auxiliary power output. The auxiliary power supply includes an input for monitoring the welder power output to determine if the welder power output is on; circuitry for determining whether a surge or spike in demand is present at the auxiliary power output; and circuitry for limiting the available power to the auxiliary power output if certain conditions are satisfied.

Abstract: A welding wire feeder includes a wire feed drive and wire feed control circuitry coupled to the wire feed drive to control the drive of welding wire towards the welding application. The welding wire feeder includes power conversion circuitry configured to receive input power and to convert the input power to welding output suitable for a welding application, output voltage sensors configured to measure output voltage, output current sensors configured to measure output current, and control circuitry coupled to the power conversion circuitry and to the output voltage and current sensors. The power conversion circuitry includes power storage circuitry configured to store energy and to discharge at least a portion of the stored energy during an overdraw event. The control circuitry is configured to control the output current during the overdraw event to maintain a stored energy value of the power storage circuitry greater than a desired minimum energy value.

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

Abstract: A system and a method for tracking and analyzing welding activity. Dynamic spatial properties of a welding tool are sensed during a welding process producing a weld. The sensed dynamic spatial properties are tracked over time and the tracked dynamic spatial properties are captured as tracked data during the welding process. The tracked data is analyzed to determine performance characteristics of a welder performing the welding process and quality characteristics of a weld produced by the welding process. The performance characteristics and the quality characteristics may be subsequently reviewed.