Abstract: A welding apparatus is configured to obtain values of one or more real-time operating parameters associated with the welding apparatus. Using the values of the one or more operating conditions, the welding apparatus is configured to determine a dynamic duty cycle of the welding apparatus, given the present/current operating conditions of the welding apparatus.

Abstract: A welding-type power system that includes an engine configured to drive an electric generator to provide a first power output. In addition to the electric generator, the system includes an energy storage system to provide a second power output. The system includes energy storage devices and charging devices that are used to charge the energy storage devices. A controller is configured to control the charging devices to provide charging power output to the energy storage devices based on the parameters related to the charge level of the energy storage devices. The controller, using data received from sensors and charge measurement devices, determines the respective charge level for each energy storage device; compares the respective charge levels to one or more threshold charge levels; and controls the charging devices to provide a charging power output to the energy storage devices with a charge level that is below a threshold charge level.

Abstract: Apparatus and methods are provided for a welding-type power system that includes an engine configured to drive an electric generator to provide a first power output. An energy storage device to provide a second power output. A controller is configured to receive one or more control signals to provide a total power output to at least one of a welding-type output or an auxiliary type output, determine proportional values for the first power output and the second power output that add up to the total power output based on a power demand signal that indicates a contribution of the first power output and the second power output, control the engine to adjust speed based on the first power output value, and control a connection from the energy storage device to provide the second power output to the welding-type output based on the second power output value.

Abstract: A system, in one embodiment, may include a portable unit having an engine, a generator coupled to the engine, a compressor coupled to the engine, and a priority load controller. The controller may be configured to adjust various loads on the engine, the generator, or the compressor, or a combination thereof, in response to a priority control scheme. A computer-implemented method, in another embodiment, may include adjusting power output to various loads on an engine, a welding generator coupled to the engine, or an air compressor coupled to the engine, or a combination thereof, in a portable welding unit in response to a priority control scheme.

Abstract: Systems and methods for providing a constant current controller for use in constant current welding applications are described. In one embodiment, a current controller controls the output current of the welding torch without directly measuring the output current of the welding torch. The current controller controls or sets a current in a primary winding of a transformer in an inverter of a welding power supply to control the output current of the welding torch.

Abstract: A motor assembly includes an electric motor with an output shaft. A motor frame houses the electric motor so that the output shaft protrudes from an end of the motor frame. A plate assembly is coupleable about the output shaft to the end of the motor frame. The plate assembly has a cavity that houses motor drive electronics. The plate assembly further defines a duct that extends between a central opening and one or more openings on an outer radial wall of the plate assembly. A fan is configured to flow air over one or more surfaces of the plate assembly and causes to flow through the duct to inhibits heat transfer between the electric motor and the motor drive electronics.

Abstract: Engine driven power supplies with output reduction are disclosed. An example engine-driven welding power supply for providing a welding-type output includes an engine, a generator mechanically linked to the engine, power conditioning circuitry, and a controller. The generator generates output power based on mechanical input from the engine. The power conditioning circuitry converts the output power from the generator to welding-type power based on a commanded output. The controller reduce an output of the power conditioning circuitry from the commanded output by an amount proportional to a difference between a speed of the engine and a commanded engine speed while monitoring the difference, decreases the output in response to determining that the reduction in the output does not result in an acceleration in the engine speed, and increases the welding-type output as the difference between the speed of the engine and the commanded engine speed decreases.

Abstract: The invention relates to an energy supply system for a mobile resistance welding machine for flash-butt welding of track rails, comprising a combustion engine (1) coupled to a generator (2) as well as a charging device (5) for charging an energy store (7), wherein the energy store (7) is a buffer element of an intermediate circuit (13) to which a welding inverter (14) is connected. In this, the energy supply system comprises an island grid to which the generator (2) is connected and which is coupled to the intermediate circuit (13) by a controlled power converter (16).

Abstract: Methods and apparatus to power a crane on a work truck using an engine-powered service pack are disclosed. An example auxiliary power system for a vehicle includes an engine, a generator configured to convert mechanical energy from the engine to electrical energy, and power conversion circuitry configured to provide electrical power to a crane to enable the crane to lift at least a portion of a rated load, and configured to convert the electrical energy from the generator to output DC power.

Abstract: A welder-generator comprising an engine operatively coupled to a generator, weld circuitry, and a cooling system. The generator is configured to produce an electrical signal. The weld circuitry includes inverter circuitry configured to control characteristics of the electrical signal. A cooling system is configured to substantially block heat generated by operation of the engine from being transmitted to the weld circuitry.

Abstract: An exemplary vehicle assembly vehicle assembly includes, among other things, a heat exchange module that manages thermal energy levels of a traction battery. An inlet conduit is configured to draw air to the heat exchange module from an area underneath a vehicle. An outlet conduit is configured to dispense air from the heat exchange module to the area underneath the vehicle. An exemplary thermal management method includes, among other things, to manage thermal energy within a traction battery of a vehicle, exchanging thermal energy between a fluid and air at a heat exchange module. The air is drawn to the heat exchange module from an area underneath the vehicle. The air is dispensed from the heat exchange module to the area underneath the vehicle.

Abstract: A vehicle includes a traction battery, circuitry including a switch and a capacitor, and a monitoring chip configured to draw power from a cell of the traction battery via the circuitry responsive to the switch being closed. The circuitry is configured to open the switch to disconnect the cell from the chip and power the chip via the capacitor for a predetermined period. Powering the chip via the capacitor prevents power down of the chip during the predetermined period. The circuitry opens the switch responsive to engine cranking.

Abstract: An engine-driven welding power supply, comprising a frame, an engine attached to the frame, and a generator attached to the frame. The generator is driven by the engine and configured to output electrical power via an electrical receptacle. Weld power conversion circuitry is integrally attached to the frame and configured to output welding-type power. A power conductor configured to provide input power to the weld conversion circuitry is configured to be manually coupled to the electrical receptacle or to an external source of electrical power. The weld power conversion circuitry is configured to convert the input power received via the power conductor to welding-type power.

Abstract: A welding machine includes a welding power supply. A generator is operatively connected to the welding power supply to supply electrical energy to the welding power supply. An internal combustion engine is configured to drive the generator. A chassis structure includes a divider wall that at least partially defines an engine compartment of the welding machine. A cantilevered engine-mounting shelf is cantilevered from the divider wall. The internal combustion engine is attached to the cantilevered engine-mounting shelf. A fuel tank is mounted within the chassis structure and located beneath each of the cantilevered engine-mounting shelf, the internal combustion engine and the generator.

Abstract: Engine-driven welding-type power supplies with portable welding units are disclosed. An example engine driven welder includes an engine, a generator configured to convert mechanical power from the engine to electric power, a chassis, the engine and the generator being mounted to the chassis, and a welding power supply configured to receive the electric power from the generator and convert the electric power to welding-type power, wherein the chassis is configured to physically hold the welding power supply, the welding power supply is physically separable from the chassis, and the welding power supply is connected to be able to receive the electric power when the welding power supply is separated from the chassis and when the welding power supply is connected to the chassis.

Abstract: Burner for a welding apparatus having a non-melting electrode, a wire feed device for a welding wire and a power feed device for introducing an electric heating current into the welding wire that is supplied. The wire feed device can be activated in two directions of advance and an electric voltage applied by the power feed device to the welding wire can be regulated to ignite an igniting arc between the tip of the welding wire and the workpiece.

Abstract: Engine driven power supplies with output reduction are disclosed. An example engine-driven welding power supply for providing a welding-type output includes an engine, a generator mechanically linked to the engine, power conditioning circuitry, and a controller. The generator generates output power based on mechanical input from the engine. The power conditioning circuitry converts the output power from the generator to welding-type power based on a commanded welding-type output.

Abstract: A welding system includes an enclosure frame. The welding system also includes a side panel having a tab extending along a bottom edge of the side panel. The tab is configured to mate with a complementary slot in the enclosure frame.

Abstract: A system for powering a hotel load in a vehicle which has a power supply with a positive pole and a negative pole, an alternator connected to the engine and in direct connection with the power supply, a starter connected to the engine and in direct electrical communication with the power supply. The vehicle also has a power inverter in electrical communication with the power supply through a pair of power inverter cables. The alternator, the starter, and the power inverter are connected in parallel and directly to the power supply.

Abstract: A hybrid vehicle including a welder that is adapted to be powered off a direct current (DC) bus generated by the electronics of the hybrid vehicle is provided. A variety of exemplary placements of the welder on or in the hybrid vehicle are provided. Additionally, a parallel hybrid configuration, a series hybrid configuration, and a series-parallel configuration including welding converter circuitry that is adapted to utilize the DC bus from the hybrid vehicle to generate welding power are provided.

Abstract: A welding system includes a housing having a front panel assembly. The welding system also includes first and second handles. The first handle is coupled to a first side of the front panel assembly and the second handle is coupled to a second side of the front panel assembly that is opposite from the first side. Each handle includes a recessed handle portion having an inner wall that forms an angle of between approximately 60 degrees and approximately 80 degrees with respect to an outer wall of the respective handle. The first and second handles are symmetrical about a central axis such that the first and second handles are interchangeable with each other. In addition, the first and second handles each include a plurality of internal tabs on both top and bottom sides of the first and second handles. The internal tabs facilitate coupling and alignment of the first and second handles with the front panel assembly.

Abstract: An electric motor with a casing in which a stator in coaxial arrangement with the motor shaft and a rotor are disposed, and a terminal box which is attached to a casing peripheral wall and in which electronic components are arranged. Between the terminal box and the casing a breakthrough is provided on the one hand and an auxiliary impeller firmly connected to the motor shaft is mounted inside the motor casing on the other hand such that an air stream can flow from the interior of the casing into the interior of the terminal box and/or vice versa when the electric motor is operating.

Abstract: A scroll pump isolates vibrations of a pump head/motor assembly of the pump from the exterior of the pump and thus, suppresses the production of airborne noise. The pump includes a sound-muffling enclosure surrounding the pump head/motor assembly, feet supporting the enclosure, and elastic vibration isolators. The pump head/motor assembly is fixed to the tops of the vibration isolators, and the sound-muffling enclosure is fixed to the vibration isolators at the bottoms of the isolators. The scroll pump also has a locking system by which motion of the pump head/motor assembly relative to the sound-muffling enclosure can be limited or prevented, and by which the sound-muffling enclosure can be hard-mounted to a support surface independently of the feet.

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

Abstract: An engine driven welder-generator including a chopper circuit and being adapted to produce an AC weld output, a DC weld output, and an auxiliary output is provided. The engine driven welder-generator is capable of selectively running at a low engine speed or a high engine speed based on operator inputs and may produce both AC and DC power outputs while utilizing the chopper circuit. The engine driven welder-generator is also adapted to provide an auxiliary output during an AC welding process and a DC welding process.

Abstract: A hybrid welder having a cabinet, an energy storage device supported by the cabinet and means for removably attaching the cabinet to the welder.

Abstract: A welding power source configured to receive an input power includes a plurality of components and supervising circuitry configurable in a plurality of modes. The plurality of components include power conversion circuitry and background power supply. The supervising circuitry is configured to distribute the input power to the plurality of components based at least in part on a mode of the plurality of modes. The plurality of modes include a welding mode configured to distribute the input power to the power conversion circuitry and to the background power supply. The plurality of modes also include a monitoring mode configured to distribute the input power to the background power supply, and to not distribute the input power to the power conversion circuitry.

Abstract: A system, in one embodiment, may include a chassis, an engine coupled to the chassis, a generator coupled to the engine, and a rotary screw compressor coupled to the chassis independent from the engine. The engine may be configured to drive both the generator and the rotary screw compressor. A method, according to another embodiment, may include isolating a rotary air compressor from an engine and a generator in a common chassis. The isolating may include separately mounting the rotary air compressor and the engine with a resilient or distance adjustable connection in between. The isolating also may include resiliently mounting the engine, or the rotary air compressor, or both.

Abstract: A system, in one embodiment, may include an engine, a compressor coupled to the engine, and an oil fill assembly coupled to the compressor. The oil fill assembly relocates an oil fill location from a bottom region of the compressor to a top region of the compressor. A system, in other embodiments, may include a compressor retrofit kit. The kit may include a first tube configured to couple with a drain or an existing oil fill disposed in a base region of a compressor. The kit also may include a second tube coupled to the first tube, wherein the second tube is configured to couple with a vent in the compressor. The kit may include a relocated oil fill section coupled to the first tube, the second tube, or a combination thereof. A system having a compressor retrofit kit attached to the case of the compressor is also provided.

Abstract: A hybrid welder having a cabinet, an energy storage device supported by the cabinet and means for removably attaching the cabinet to the welder.

Abstract: A hybrid welder having a motor-driven welder assembly including a motor; an energy storage device electrically connected to the motor-driven assembly; a heat transfer assembly, the heat transfer assembly being in thermal communication with the motor and the energy storage device, wherein the heat transfer assembly is selectively adaptive to transfer heat from the motor to the energy storage device.

Abstract: The invention described herein generally pertains to an apparatus for a welding operation having peripheral attachments combined with welding capability. Particularly, various welders can include powered tools integrated into the welder to expedite welding operations while increasing equipment convenience, reliability, and survivability. In embodiments, a grinder can be built into a welder. In embodiments the welder can be an engine driven welder or hybrid welder.

Abstract: A hybrid power supply for a welder including a controller; an energy storage device electrically connected to the controller to provide power to the controller; an engine having a drive shaft, the engine including a generator adapted to provide power to the controller; a power take off including a transmission having a first portion coupled to the drive shaft and a second portion attachable to an external device; and wherein the controller is adapted to supply power to an implement for a welding operation, the controller regulating the power output from the energy storage device and the engine based on the power required by the implement and the external device.

Abstract: The invention described herein generally pertains to a system and method for a welding device and, in particular, a hybrid welding device, that leverages a renewable energy source for a source of electrical current. The welding device can include one or more renewable energy kits that harvest renewable energy sources for performing a welding operation or a powering at least one of a device or component external to the welding device. The welding device includes renewable energy component that collects an input to convert to an electrical current that can be used as a replacement current, a supplemental current, or a complimentary current.

Abstract: The invention described herein generally pertains to a system and method for including a port component to an engine driven welding device. An engine driven welding device includes a motor that is a power source for a welding operation, wherein a first circuit converts a voltage from the power source to a second voltage. A port component utilizes the second voltage as a power source for an external device. Additionally or alternatively, the port component utilizes the second voltage to power a data transfer between the external device and the engine driven welding device.

Abstract: An engine driven welder-generator including a chopper circuit and being adapted to produce an AC weld output, a DC weld output, and an auxiliary output is provided. The engine driven welder-generator is capable of selectively running at a low engine speed or a high engine speed based on operator inputs and may produce both AC and DC power outputs while utilizing the chopper circuit. The engine driven welder-generator is also adapted to provide an auxiliary output during an AC welding process and a DC welding process.

Abstract: A system, in one embodiment, may include a chassis, an engine coupled to the chassis, a generator coupled to the engine, and a rotary screw compressor coupled to the chassis independent from the engine. The engine may be configured to drive both the generator and the rotary screw compressor. A method, according to another embodiment, may include isolating a rotary air compressor from an engine and a generator in a common chassis. The isolating may include separately mounting the rotary air compressor and the engine with a resilient or distance adjustable connection in between. The isolating also may include resiliently mounting the engine, or the rotary air compressor, or both.

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: Systems and methods are provided for a torch power system using a multi-stage compressor. In one embodiment, a system includes a torch power unit that includes a compressor having multiple compression stages. A method of operation is provided that includes compressing a gas via a multi-stage compressor in a torch power unit. A method of manufacturing a torch power unit is provided that includes providing a multi-stage compressor for a torch power unit and mounting the multi-stage compressor inside an enclosure of the torch power unit. Another system is provided that includes a plasma cutting circuit, a multi-stage compressor, a motor coupled to the compressor, and a compressor controller.

Abstract: An engine driven welder-generator including a chopper circuit and being adapted to produce an AC weld output, a DC weld output, and an auxiliary output is provided. The engine driven welder-generator is capable of selectively running at a low engine speed or a high engine speed based on operator inputs and may produce both AC and DC power outputs while utilizing the chopper circuit. The engine driven welder-generator is also adapted to provide an auxiliary output during an AC welding process and a DC welding process.

Abstract: A system, in one embodiment, may include a portable welding unit having an engine, a generator coupled to the engine, a compressor coupled to the engine, and a smart battery charger coupled to the generator. A system, in another embodiment, may include a battery charger, wherein the battery charger is configured to monitor a temperature of a battery, an ambient temperature, a battery charge time, or a combination thereof. A system, in a further embodiment, may include at least one circuit having a welding control circuit and a battery charge circuit. The battery charge circuit may be configured to adjust an output based on a battery type, a battery voltage rating, a sensed feedback, a battery test, or a combination thereof.

Abstract: An engine driven welding machine that includes a frame with lower tubular portions that extend across the ends of the frame. The lower tubular portions make it easier to lift the engine driven welding machine onto an elevated surface, such as the bed of a truck. The frame may include two different lifting portions that extend across the same side or end of the frame at different levels. For example, two tubular portions of the frame may extend generally horizontally across the same side or end of the frame to provide two lifting areas at different levels of the frame.

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 welding system includes an engine configured to drive a generator to produce a first power output. The welding system also includes a battery configured to discharge energy to produce a second power output. In addition, the welding system includes an auxiliary charger coupled to the battery and the generator. The auxiliary charger is configured to maintain a float charge of the battery when the first and second power outputs are reduced from a base load.

Abstract: The invention described herein generally pertains to a system and method for a welder system that includes a weld power generator and an auxiliary power generator in which the auxiliary power generator is adjustable between a first frequency and a second frequency for a power output to at least one outlet. The first frequency can correspond with a first national standard for a first country and the second frequency can correspond with a second national standard for a second country.

Abstract: An engine driven welder includes a generator configured to provide an electrical output, an engine coupled to the generator, an air compression system coupled to the engine, a first welding system coupled to the generator, and a second welding system. The engine is configured to drive the generator, and the air compression system is configured to provide a pneumatic output. The first welding system is configured to provide a first weld output, and the second welding system is configured to provide a second weld output. The second weld output is independent of the first weld output in an independent mode, and the second weld output is combined with the first weld output as a combined weld output in a parallel mode.

Abstract: An integrated welder and air compressor combination includes a housing having an engine, weld current generator, and a belt-driven air compressor. A pulley arrangement is coupled to the engine, with the centers of the pulleys in a co-planar arrangement to enable driving the air compressor and engine accessory pulleys with a single belt. The engine accessory pulleys can drive, for example, one or more of an alternator, fan, or pump.

Abstract: An electric arc welder that includes a energy storage device and non-battery power source for the formation of an electric arc. The welder also includes battery charging circuit that controls the charging of the energy storage device by the non-battery power source. The non-battery power source can include an engine driven electric generator, power grid or a fuel cell.

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: Embodiments of a pendant associated with a multi-process welding power supply that allows a user to switch processes and reverse an output polarity while located remotely from a power supply unit are provided. Certain embodiments include a pendant with a wire spool and wire feeder drive circuitry that is configured to activate spooling during MIG welding. Control circuitry that may include processing circuitry and memory is provided. The control system may disable redundant controls on the power supply unit user interface when the power supply unit is connected to the pendant via a supply cable. Additionally, the control system may set the process, set the polarity, enable or disable a wire feed, and enable or disable gas flow according to inputs received via a user interface on either the power supply unit or the pendant.