Abstract: A system, in one embodiment, includes an engine, a generator coupled to the engine, a compressor coupled to the engine, and a controller configured to soft start the compressor. A method, in another embodiment, includes soft starting an air compressor in a portable welding unit having the air compressor, an engine coupled to the air compressor, and a welding generator coupled to the engine.

Abstract: A system 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. The smart battery charger may be configured to monitor a temperature of a battery, an ambient temperature, a battery charge time, or a combination thereof. The smart battery charger may also 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: 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: 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: Methods and systems for housing a consumable storage bin in addition to structural, thermal management, pneumatic, and/or electronic system components in a single multifunctional component within a plasma cutting power supply are provided. One embodiment of the present disclosure relates to a consumable storage bin, which fits into a consumable storage area in the power supply unit and is accessible to a user. In one embodiment, the consumable storage bin may be eliminated, leaving only the consumable storage area in which racks, snaps, friction-fit retention features, and so forth, may be placed to hold the consumables and ensure easy user access.

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 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: 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.

Abstract: Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

Abstract: A portable engine driven welder is provided that has a case enclosing an internal combustion engine and a welding generator, and a running gear that is attached to the case. The running gear includes a pair of rails and a pair of leading wheels connected to the rails toward the back wall of the case. A pair of trailing wheels is connected to the rails toward the front wall of the case. The leading and trailing wheels have different resiliency values with the leading wheels being more resilient or flexible than the trailing wheels. This allows the leading wheels to act like a suspension system for the portable engine driven welder and running gear by soaking up or absorbing impacts instead of transmitting them therethrough so as to reduce exposure of the portable engine driven welder to such impacts.

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 sensor feedback and 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 sensor feedback and a priority control scheme.

Abstract: A welding system includes an engine-driven welder generator that produces welding power. A welding torch receives the welding power and applies it to a stick electrode to initiate and maintain a welding arc. A parameter of the welding power, such as voltage, is monitored, such as to determine whether spikes occur during a short time after arc initiation. Based upon the monitored parameter, the engine speed is controlled. The engine speed may be increased or maintained at an elevated level if the monitored parameter indicates that particular types of electrode are being used, such as XX10 or cellulose electrodes.

Abstract: An engine-driven welder generator is controlled based upon power draw for welding and other applications. Once a welding arc is initiated, the power draw is monitored. The engine speed, and therefore the power output of the generator, may be increased or maintained based upon the power draw. The power draw may include both welding power draw and auxiliary power draw. The engine speed is increased in increments. The initial engine speed and subsequent increments may depend upon particular welding processes or regimes.

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: 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: Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: Embodiments of an enclosed welder that includes a recess disposed at a depth in a rear panel of the enclosure are provided. The recess may include at least one of an engine air filter, a blower housing, and a recoil start. The depth at which the recess is set back from the rear panel may be such that the engine air filter, the blower housing, and the recoil start each do not extend outward beyond the rear panel. A first air source may be configured to enter the enclosed welder via the air filter and combust fuel within an engine. A second air source may further be configured to enter the welder via the blower housing and cool the engine.

Abstract: A welding system includes a power source configured to generate power and deliver the power to a welding electrode. The power source comprises a positive stud and a negative stud. The welding system also includes control circuitry configured to determine whether the welding electrode is properly connected to the positive and negative studs of the power source.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

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 welding generator system, in certain embodiments, has a generally vertical arrangement of a drive and a generator. The welding generator system may include a motor and a generator coupled to the motor, wherein the generator includes a rotor having an axis oriented in a generally upright direction relative to a base portion of the welding generator system. The welding generator system also may include a thrust bearing configured to support an axial load of the rotor, and a welding power system coupled to the generator.

Abstract: An engine driven welding system includes two power generators, each having a rotor and a stator. Each rotor is mounted on a respective drive shaft, with one of the drive shafts being driven by the engine and the other drive shaft being releasably coupled to the engine driven drive shaft. This provides a modular type construction of the welding system, in that the outboard power generator can be selected or changed as needed for a particular application. The coupled drive shafts are supported by two bearing assemblies. Also disclosed as additional features for any welding system power supply is a removable plate having one or more connectors releasably attached thereto for facilitating installation of an electrical component for a welding system power supply; and also a power switch having a member that restricts rotational movement of the switch.

Abstract: A power supply apparatus includes an air path extending longitudinally, a fan that blows air into the air path in a direction intersecting a longitudinal direction of the air path, and a plurality of electronic components arranged in the longitudinal direction. Each of the electronic components is cooled by air passing through the air path. With this configuration, it is possible to efficiently cool the electronic components without compromising the flexibility of arrangement of the various electronic components. Also, a dust removal operation can be readily performed without the possibility of damaging the fan.

Abstract: The present embodiments provide a system having a motor, a compressor having a compression device configured to increase a pressure of a gas, a clutch configured to selectively transfer torque from the motor to the compressor to drive the compression device, and a controller configured to disengage the clutch if the pressure of the gas in the compressor meets or exceeds a first threshold pressure.

Abstract: A constant voltage (CV) welding process power supply is provided. The power supply includes a controller configured to detect a short circuit event in a CV welding process and increase a welding current based upon a periodically computed voltage error and a first gain to attempt to clear the short circuit event. The controller is further configured to detect whether the short circuit event has cleared after the first current increase. If the short circuit event has not cleared, the controller increases the welding current based upon the periodically computed voltage error and a second gain higher than the first gain.

Abstract: A welder includes a housing enclosing one or more welding circuits communicated with power output studs for establishing a welding arc. A generally rigid bracket may be included that is affixed to an exterior of the housing, which may include first and second spaced apart support arms extending from a bracket, where the first support arm includes a first supporting surface facing a first direction, and where the second support arm includes a second supporting surface facing a second opposite direction for supporting the associated welding gun in a cantilevered configuration. A cable cradle is also included that extends from a second, distal end of the bracket.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: A power management system, in certain aspects, may utilize direct load sensing feedback from the prime mover (e.g., engine), thereby reducing the possibility of overloading the prime mover. The use of direct load sense feedback from the prime mover can then be used with additional feedback, such as prime mover RPM feedback and individual output load sensing feedback, to directly control the output loads and set the primary power sources rpm set-point to better manage the power available and reduce the possibility of overloading the primary power source.

Abstract: A system and method are provided for controlling an internal combustion engine driving a generator/welder or a stand-alone generator. The engine and/or the generator is controlled based upon settings for welding. Controlling the engine may include altering the engine speed based upon a detected demand on the generator and/or operating parameters of a welder.

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: A DC arc start function for a welder. The arc start function is realized using a universal input DC regulator coupled to a DC to DC converter that produces a regulated DC voltage that is sufficient to strike an arc at an electrode of the welder.

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: A system and method for welding arc termination are provided. In an exemplary embodiment, a method for controlling a welding process includes receiving a signal indicating an operator intention to terminate a welding arc and stopping advance of a welding wire in response to the signal. The method also includes reducing a conduction angle for switching of solid state switches that generate welding power in response to the signal.

Abstract: Welding systems including a hydraulically driven welding power supply adapted to utilize hydraulic primary power to generate a first welding output for a first welding operation and a second welding output for a second welding operation are provided. Such welding systems may include control circuitry coupled to the hydraulically driven welding power supply and adapted to enable the hydraulically driven welding power supply to provide the first welding output and the second welding output at the same time to enable a first welding operator and a second welding operator to perform the first welding operation and the second welding operation, respectively, at the same time.

Abstract: An engine welder having a single rotor and a single stator, and methods of distributing electrical power capacity of the engine welder to various welding windings and auxiliary windings of the engine welder. The single rotor is driven at saturation current and independent control of the welding outputs is accomplished on the stator side of the engine welder. Means for supplying the full electrical power capacity of the engine welder to a single stator welding winding are provided. Furthermore, means for distributing the electrical power capacity of the engine welder between welding windings and/or auxiliary windings of the single stator are provided.

Abstract: Exemplary embodiments of the present technique relate to a welding storage structure. In one embodiment, a welding system includes a welding chassis and a storage structure that rotates outwardly from the welding chassis. In another embodiment, a welding system includes a welding storage unit having a storage base with a plurality of storage compartments, a cover removably disposed over the plurality of the storage compartments, and a rotatable chassis mount configured to couple the welding storage unit rotatably to a welding chassis.

Abstract: An engine driven welding system includes two power generators, each having a rotor and a stator. Each rotor is mounted on a respective drive shaft, with one of the drive shafts being driven by the engine and the other drive shaft being releasably coupled to the engine driven drive shaft. This provides a modular type construction of the welding system, in that the outboard power generator can be selected or changed as needed for a particular application. The coupled drive shafts are supported by two bearing assemblies. Also disclosed as additional features for any welding system power supply is a removable plate having one or more connectors releasably attached thereto for facilitating installation of an electrical component for a welding system power supply; and also a power switch having a member that restricts rotational movement of the switch.

Abstract: A hybrid welding device including a fuel cell and an energy storage device that cooperate to power a welding operation and/or an auxiliary operation are provided. In some embodiments, the hybrid welding device may also include an engine coupled to a generator that is configured to supplement the power provided by the fuel cell and/or the energy storage device. The hybrid welding device may be adapted to provide power for a welding operation and/or an auxiliary operation when operated as a standalone unit and/or when connected to a primary source of utility power.

Abstract: An integrated welder, generator and hydraulic unit that includes a housing that at least partially contains components of a welder, generator and a hydraulic pump. An engine, an electric current generator, and a hydraulic pump are at least partially mounted in the housing. The electric current generator is at least partially connected to the engine to be at least partially driven thereby. The hydraulic pump can be at least partially powered by the electric current generator or the fuel powered engine during the operation of the engine. The integrated welder, generator and hydraulic unit can also include an air compressor.

Abstract: A system and method of controlling available power of an auxiliary output of a welding-type power source is disclosed. The welding-type power source is configured to supply power to a variable combination of a welding-type output and the auxiliary output and includes a controller configured to detect a load on the auxiliary output. The controller is configured to monitor an engine operating parameter of the welding-type power source and to limit the amount of power provided to the auxiliary output to an amount of power capable of being generated by the engine at a current engine condition.

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: 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 power source for welding includes electrical components that generate heat during a welding operation, a fume extractor for removing welding fumes from a welding site during a welding operation, and a filtration device for filtering the welding fumes to produce filtered air such that the filtered air helps cool the electrical components.

Abstract: A DC arc start function for a welder. The arc start function is realized using a universal input DC regulator coupled to a DC to DC converter that produces a regulated DC voltage that is sufficient to strike an arc at an electrode of the welder.

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: 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: 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.