Abstract: A method and system for controlling a welding cycle of an arc welder comprising: a number of digital programs stored in a digital memory device, with each of the programs including a plurality of digitally coded welding parameters indicative of selected functions of a specific welding cycle; a weld controller for converting the selected functions of a digital program into welding parameters at the output of the welder; a display panel having a group of switches located in a given pattern and a decoder network at a selected position for creating a decoded signal indicative of the activation pattern of the decoder network; means responsive to the decoded signal for activating said switches in either a first condition where the switches activate means for modifying a selected one of said digital programs or a second condition where said switches activate means for creating a program select signal corresponding to a given digital program; means responsive to a program select signal for selecting one of the progra

Abstract: A remote control device for welding machines including a control device constituted by an encoder and a decoder in the welding gun. Modulation signals generated by the decoder are directly transmitted via the welding wire to the control device, so that the control device may regulate the power output of the welding machine.

Abstract: A battery-powered welder delivers limited DC current to a workpiece without substantial reduction in applied voltage. The DC current is limited by utilizing a tungsten member in series between the battery and an arcing electrode. There is specifically disclosed a TIG welder embodiment.

Abstract: A microprocessor-controlled arc welding power supply is disclosed. An silicon controlled rectifier ("SCR") bank is used to generate a direct current arc welding current under program control. Positive sychronization is provided by the microprocessor using a phase locked loop and a polarity detector, so that the gating signals applied to the SCRs are correctly timed. Optimum tradeoffs between hardware and software are accomplished by using look up tables to store correction factors that can be quickly accessed during execution, and by using timers as smart interface chips to fire the SCRs at the same angle during each cycle until changed or updated by the microprocessor. The arc welding power supply is capable of operating in a constant current or constant voltage mode without rewiring the circuit.

Abstract: This electric stud-welding device includes a welding gun for a stud or bolt to be welding to a workpiece, and a control device. The latter consists of a welding current source and a setting device for welding time and welding current. The welding gun and the control device are connected through two welding current lines. A pilot current circuit is present, using only the two welding current lines (5, 6). Also present is a setting device (10), coordinated with the welding gun (3), which is switched into the pilot current circuit. In the control device (2), there is a sensor (9) which, dependent on the control signals produced by the setting device (10) each time, after the actuation of the selective switches or setters (13, 14) arranged thereon, controls the control device (8), present in the control instrument, for the welding time and the welding current.

Abstract: Disclosed is a control unit for welding apparatus which feeds wire in the presence of a shielding gas to a workpiece at different rates with different heat inputs in accordance with the wire feed rate. The control unit is designed so that through a single control element the workman may adjust the wire feed rate and simultaneously and automatically adjust the heat input. When different wire types are employed in different welding processes, adjustments in the control unit are provided that allow the workman to reset the relationship between the wire feed rate and heat input in accordance with the type of wire being used. A hot-start feature is provided so that more power is applied for a predetermined manually adjusted time period during start-up.

Abstract: The invention is a welding torch with a control means on the torch itself for adjusting welding current. This control means has a thumb button which can be actuated by the welder to turn the torch on or off and to adjust the current to an appropriate value for the weld being made. A latch means at one extreme of its travel is provided to hold the thumb button in the off position. This prevents the torch from being accidentally actuated by inadvertently moving the button.

Abstract: An electric welding control circuit incorporates a mode selection switch to enable the welder to be used in a selected one of several operational modes, such as a rod welder, a MIG, a TIG or a spot/stitch welder. A wire feed motor is used in the MIG mode to feed welding wire to the electrodes. A regulating circuit controls the speed of the wire feed motor as a function of the welding electrode voltage. A zener diode in the regulating circuit turns on a switching transistor to cause the feed motor to run at a normal speed when the voltage is between predetermined limits and a second zener diode senses a loss of arc to slow the feed. In a spot/stitch mode, a timer is used to time the spot periods, the timer operation being dependent on the presence of an arc as detected by the regulating circuit so as to commence the timed period when the arc is struck.

Abstract: A semi-automatic hot wier TIG (Tungsten Inert Gas) welding equipment comprising: a portable TIG arc torch; a portable filler wire feed torch; a hot wire switching power source for energizing the TIG arc torch, the filler wire feed torch and a base metal; a filler wire feeding device for feeding the wire to the wire feeding torch at a desired rate; a welding condition control device for controlling wire heating power so as to provide wire heating power commensurate to the wire feed rate; means for measuring the resistance value of the wire extension section between the terminal end of the wire and the terminal end of the filler wire feed torch; and means for controlling said filler wire feeding means to change the wire feed rate in response to the detected wire extension.

Abstract: Apparatus and method are provided for permitting human voice control of a welding system. A human operator, remote from a welding power supply, uses a welding torch connected by a power line to the welding power supply. The human operator is provided with an audio transmitter which permits the operator to adjust the welding power supply through verbal commands. The verbal commands are issued by the human operator, and are transmitted through a receiver, a voice recognition unit, and a computer, which is electrically connected to deliver power control signals to the welding power supply to thereby adjust the power delivered to the welding torch. The operator may also issue verbal commands to start and stop an internal combustion engine which drives the welding power supply, when such an engine is used. Additionally, when the welding process incorporates a consumable wire electrode, the operator may verbally alter the speed at which the wire electrode is fed through the welding torch.

Abstract: A method of protecting eyes from welding rays in arc welding and an apparatus therefor are disclosed which are capable of closing a filter plate over a period from right before the generation of arc welding rays to the termination of the generation to fully intercept the rays, to thereby effectively protect the eyes of an operator from the rays. The invention is constructed in a manner such that a controller carries out the on-off control of a voltage applied from a filter power source to a PLZT filter plate depending upon a signal supplied from a detection circuit thereto when the detection circuit detects a built-up current occurring in a welding current, to thereby carry out the actuation of the filter plate.

Abstract: An improved welding power supply control circuit is disclosed. The control circuit, which incorporates a microprocessor, simultaneously adjusts the power supplied to a welding electrode and the speed of the electrode, in accordance with a selected power/speed relationship table or curve. The power/speed relationship of a selected table can be further modified manually, as by a potentiometer, to optimize the weld. Feedback circuitry senses the frequency of the weld and the weld voltage, to regulate the power and to modify the slope of the voltage/current output curve, respectively.

Abstract: An arc welding control system wherein the welding current is held to a very low value during the time a welding electrode is coupled with a workpiece. When the welding electrode is disengaged from the workpiece, a very low current pilot arc is established. Then, arc voltage monitors effect, first, an increase in the current of the pilot arc and then the closing of a welding current contactor. Both shielded metal arc welding and gas tungsten arc welding modes are accommodated; and, in the latter, when a too low arc voltage condition is detected, arc voltage monitors effect the opening of the welding current contactor for such time as the too low arc voltage condition exists. While the welding current contactor is open, a low current pilot arc is maintained until the too low arc voltage condition is corrected.

Abstract: A control circuit for an electric arc welder is responsive to the operation of a torch or gun mounted control switch. A first comparator has one input connected to the gun switch and the other input to a reference voltage source. When the gun switch is closed, the output of the comparator will cause a control relay to be energized. When a welding arc is established, a reed switch closes and provides an input to a second comparator which effectively provides a latch to hold the control relay energized. After a predetermined time delay, typically in the order of 1 second, a timer circuit will provide an output to one input of a third comparator, the other input of which is connected to the gun switch. A subsequent closure of the gun switch will caused the output of the third comparator to change the level of the reference voltage, changing the outputs of the first two comparators, thereby removing the latch and deenergizing the control relay.

Abstract: A circuit for controlling the power supply to an electrode of the shielded type, such as that used in a shielded metal arc welding process (SMAW) whereby to protect a user from electric shocks. The control circuit is a protection circuit which serves to protect welders against electric shocks by decreasing the circuit voltage between the electrode tip and the workpiece to be welded. An AC or DC power supply may be used to feed the electrode. The control circuit is comprised of a high impedance voltage source applied to the electrode, a detection circuit for determining the level value of the impedance appearing between the electrode and the workpiece. The detection circuit compares the impedance thus detected with a threshold impedance and generates a control signal when the detected impedance is lower than the threshold impedance. The control signal operates a driver circuit which energizes a power feed device serially connected between the electrode power supply and the electrode itself.

Abstract: The specification describes a control unit for use with the welding gun of an arc welding assembly. A single adjustable means in the welding gun effects changes in the control unit to regulate welding voltage as well as the speed at which the electrode wire is fed to the welding site.

Abstract: A portable wirefeed and control apparatus for use in consumable electrode arc welding systems which is capable of being powered by conventional AC or DC variable voltage or variable current supplies without modification of the power supply or the wirefeed and control apparatus. The portable wirefeed unit incorporates a wirefeed motor, a supply of weld wire, optional gas controls, and voltage regulating and protective control circuits all powered at welding arc voltage carried by the welding current supply conductor. The unit is circuit connected to the power supply by means of a single welding electrode supply conductor and a ground return. Electrode power, weld wire, optional shielding gas supply and welding gun control switch conductors are carried in a single flexible conduit extending between the control unit and a remote welding gun and wirefeed speed and thus wirefeed rate are partially responsive to variations in welding arc voltage.

Abstract: A three-phase thyristor (42, 43) controlled welding output supply requiring only a single firing pulse of short duration per phase per half cycle is shown. Once a firing pulse has been provided (122), a holding impedance (40) connected between the output electrodes (32, 34) is provided to the neutral terminal (18) of a wye wound secondary (17) to provide a path for holding current independently of the load presented by the arc. An improved firing control circuit includes in addition to the normal firing capacitor (82), a negative phase angle impedance (86, 87, 88) attached to one end of a conventional breakdown device (117) used to fire a master thyristor gate (119). Stepped up voltage (60) is provided to the control circuit for greater noise immunity. Also shown is a remote control (151) for controlling a reversible motor (150) to drive through a slip clutch (140), the main voltage controlling variable impedance (80).

Abstract: A fail-safe voltage reducing circuit for an arc welder. The welding transformer has two primary windings connected in parallel across a power source. After an arc is struck, if the arc is then broken for a predetermined time period, the circuit automatically disconnects one of the primary windings from the power source, thereby reducing the voltage across the welder's output terminals to a safe standby voltage lower than the full open circuit voltage. If the voltage has not been reduced after a second predetermined time period, the fail-safe feature of the circuit automatically disconnects both primary windings from the power source, thereby completely removing all power from the welder.

Abstract: A method for controlling selected switching between preset welding schedules in a MIG welding operation, in response to operation from a single control switch having only on and off signal selections.

Abstract: A solenoid operated, ratchet-type step motor incrementally advances the rheostat of a welding apparatus in opposite directions to control welding current. The solenoids are pulsed in response to reception of a frequency and digitally coded radiant energy signal by a receiver to which signals are transmitted from a remote transmitter having direction selecting push button switches.

Abstract: An electric arc welding control unit for controlling welding parameters such as voltage and wire feed rate. Manual potentiometer controls are operated from the outside of the unit to select values for the welding parameters. An override switch inaccessible to the outside of the control unit defeats the exterior controls and actuates second control means comprising interior controls which can be preset to define desirable schedules of welding parameter values. A selector switch is used to select one of the welding schedules. When they are defeated the exterior controls become dummy controls which do not affect the welding schedules.

Abstract: DC inert-gas welding apparatus with variable welding current has an automatic controller for reducing the welding current during the various stages of the welding process. The decrease in current is controlled by a single contact of a stepping circuit. A limit switch responsive to the output voltage of the welding apparatus controls the stepping circuit. The circuitry includes a variable search current adjusting resistor and a variable crater filling current adjusting resistor: these resistors are mutually independently variable, and the latter is connected to the tap of a potentiometer for adjusting the welding current. A variable ratio voltage divider connects the stepping circuit via a storage capacitor to the current setting circuit.

Abstract: Apparatus for the remote control of mains operated DC and AC welding machines without any additional cable to the working place, comprising a portable regulating device adapted to be connected into the welding current circuit between the electrode or the electrode holder and the workpiece or a clamp therefor. This device selectively generates different control signals in the welding cables when receiving a current supply through the welding cables, and a regulating circuit in the welding machine is adapted to receive these control signals through the welding cables from the regulating device and to cause regulation of functions in the welding machine or in association therewith in response to the control signals.

Abstract: A hand-operated remote control unit has a housing containing a rotary potentiometer whose shaft carries a pinion which is driven by a rack having a spring loaded push button attached thereto. An eccentric cam is mounted on the potentiometer shaft adjacent a microswitch in which the cam surface is in contact with the switch when the push button is in its unactuated position. When the push button is actuated, the cam rotates releasing the switch, and the rack and pinion varies the resistance of the potentiometer to vary the welding current. A plurality of hat section holders are positioned on different surfaces of the housing for mounting an adjustable ring-shaped clamp having bayonet extensions thereon which fit into the hat section holders. The adjustable ring-shaped clamp which has a set screw therein is adapted to be adjustably mounted on the handle of the welding torch. The adjustable clamp may be moved up and down to a desired position on the welding torch and the welding torch may be rotated 360.degree.

Abstract: The controls for a arc welder are located at the rod holder. The rod holder controls include push buttons which cause electrical motors geared to the control shafts to rotate in either a forward or reverse direction.

Abstract: The position of the main rheostat on an arc welding machine determines the pre-set welding current. An operator, working at a location remote from the welding machine, carries a pen-type adjustable rheostat which carries calibrations indicative of various percentages of the pre-set welding current. There are no extra electrical connections, such as wires, between the remote rheostat and the welding machine. If the operator wishes to change the magnitude of the welding current, he need not return to the main rheostat at the welding machine, but instead merely sets the remote rheostat for the percentage of pre-set current desired, and inserts the remote rheostat between the electrode holder and the workpiece. The minimum resistance of the remote rheostat is sufficiently high to prevent an arc from being struck. A current transformer in the welding machine senses the output (calibrating) current flowing through the welding cable.

Abstract: An improved apparatus for alloying a surface of a workpiece of the type in which an electrode, formed of the alloying material, is connected to a pulse generating machine which creates repetitive spark discharges between the electrode and the workpiece when the electrode is in engagement with the workpiece, the improvement being a safety circuit which prevents energization of the electrode until it is engaged with the workpiece.

Abstract: A switching system that provides means for a welder to make precise point arc strikes and to prevent a welder from receiving an electrical shock while he is inserting a welding electrode into the electrode holder. The system includes an automatically controlled switch which prevents uncontrolled open circuit voltage from existing at the electrode holder when the welding arc is interrupted. Additionally, the system includes a manually operated switch for reestablishing full potential on the electrode holder to facilitate striking an arc, with the flow of current to the welding arc being continuous as long as the arc is maintained after the manual switch is released.

Abstract: A remote control unit for closing a normally open contactor in response to closing of a normally open gun switch in a portable wirefeed arc welding system having a power source including the contactor, a portable wirefeed unit, a welding gun, a ground cable interconnecting the power source and the work, an electrode power cable interconnecting the power source and the wirefeed unit and gun, and control leads interconnecting the wirefeed unit with the work and the gun; wherein a capacitor in the control unit is operable to place an override current on the ground and electrode power cables in response to closing of the gun switch, and sensing means comprising a sense relay are operable in response to such override current to effect closing of a normally open cycle hold delay relay and the contactor. The cycle hold delay relay, in turn, closes a fourth or rearming delay relay which opens the circuit to the sense relay.

Abstract: A two conductor, nonpolarized, low voltage control cable is used in conjunction with the single conductor welding cable to achieve excellent stability of wire feed motor speed without the use of silicon controlled rectifiers or other three terminal semiconductor devices. One conductor of the control cable is used as a ground return path for the wire feed motor. The voltage across the wire feed motor is the difference between the welding power supply voltage and a second control voltage which tracks variations in the power supply voltage due to fluctuations of the AC input to the system. When greater wire feed speeds are desired, the control voltage may be driven below ground and wire feed motor speed stability is obtained by operating the motor in a region where angular velocity is relatively insensitive to incremental changes in terminal voltage. When the control cable running from the power supply control circuitry to the remote unit is severed, it may be spliced without regard to polarity by the user.

Abstract: A control station for use with multiple operator power supplies in a semiautomatic welding system is disclosed. The system utilizes a constant-potential multiple operator unit, suitable for gas-metal arc spray transfer welding, to which control stations may be connected to provide satisfactory short-circuiting arc operation for selected operators. The control station comprises a plurality of resistors selectably connectable in specified parallel relationships through switching means and an iron core inductor to provide the required operating characteristics for short-circuit welding.

Abstract: A welding machine for automatically welding abutting workpiece portions in which the workpiece portions are aligned by a gauge and after being clamped in such a position, the gauge is automatically removed and the clamped ends are moved into abutting relationship to each other to be welded together. After the weld is completed the gauge is moved automatically to engage and eject the welded part and at the same time position the gauge and place the machine in condition to receive the next part to be welded.

Abstract: Control means for a welder of the "tungsten-inert-gas" type which senses even momentary engagement of the workpiece by the torch to initiate gas flow. The welding region is initially purged by the gas. After a predetermined timed interval the output of the welding power source is elevated to a level sufficient to cause the striking of an arc.Gas flow is maintained during the welding operation and for a predetermined time interval after extinction of the arc is detected.Means are also provided for visually indicating gas flow and further for automatically preventing the striking of an arc when gas flow is exhausted.Means are provided so that the welder power supply may also be turned on automatically to eliminate the need for foot or hand-operated switches conventionally used to turn on the welder power supply.Sensing means are also provided to protect the torch from becoming accidentally "welded" to the workpiece.

Abstract: The controller automatically and remotely controls the stopping and running of an internal combustion engine coupled to a DC generator that supplies DC power to the welding cables of an arc welding machine. The engine has a starter, an ignition, and an intake manifold. A vacuum-actuated switching means is coupled to the intake manifold and is responsive to the vacuum produced therein. A switching circuit is coupled to and is controlled by the vacuum-actuated switching means. A starter and an ignition are coupled to the switching circuit. A timer having a predetermined timing interval is coupled to the switching circuit, to the welding circuit, and to the ignition.

Abstract: The control unit comprises an elongated body having a forward torch mounting portion. Rearwards of the torch the body houses a linear potentiometer which includes an upstanding control arm for its movable contact. An off-on switch is located within said body, in a position to be contacted and operated by the control arm. A thumb button controlled sliding control member is attached to the control arm. In use, the user grips the mid portion of the body and places his thumb on the thumb button. He uses a simple linear movement of his thumb to both control the linear potentiometer, for varying the welding current, and to operate the off-on switch, for turning the arc welding machine on and off.

Abstract: A welding torch handle including electrical control means thus enabling a welder, by the control on the handle, to vary the welding current supplied to an electrode in the torch head fitted to the handle. The handle is characterized by employing a linearly actuated control that can continuously vary current applied to the electrode from 0 amps to the full setting on the welding power supply. This control eliminates foot, hand held, or motor driven controls and provides convenient single-handed current control by the welder.

Abstract: The controller automatically and remotely controls the stopping and running of an internal combustion engine coupled to a DC generator that supplies DC power to the welding cables of an arc welding machine. The engine has a starter, an ignition, and an intake manifold. A vacuum-actuated switching means is coupled to the intake manifold and is responsive to the vacuum produced therein. A switching circuit is coupled to and is controlled by the vacuum-actuated switching means. A starter and an ignition are coupled to the switching circuit. A timer having a predetermined timing interval is coupled to the switching circuit, to the welding circuit, and to the ignition.