Abstract: A fueling assembly for a fuel tank positioned in an engine driven welder. The fueling assembly includes a filler tube, a fuel level monitor and a grommet. The filler tube has a bottom portion and a top portion. The fuel level monitor includes a fuel level sensor position in the fuel tank and/or filler tube. The fuel level monitor includes a fuel level indicator positioned on the housing to enable an operator to view the fuel level indicator and the opening used to direct fuel into the filler tube during the filling of the fuel tank.

Abstract: An integrated multi-function, portable power and utility apparatus having a single prime mover device having a single engine device having at least two opposite extending rotary output devices wherein the engine device turns one output device clockwise and the other counterclockwise without belts, pulleys, chains or gears. An electric generator device is directly connected to one of the two rotary output devices and has a plurality of electric output devices. A fluid pumping device is directly connected to the other rotary output device. The fluid pumping device is preferably a rotary screw-type air compressor.

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 remote drain and filter arrangement for a portable engine-driven generator is disclosed that positions the oil filter and oil drain at a location outside the enclosure of the generator. The arrangement generally consists of an oil filter assembly and oil drain assembly. The oil filter assembly includes an oil filter adapter used to interface with the oil filter and is coupled to the engine via oil conduits. The oil drain assembly includes an oil drain conduit and a flow control device that allows the oil to be drained from a location outside of the enclosure of the generator. A pump can be used to allow for sufficiently longer oil conduits. The invention is retrofittable to current engine-driven generators and can also be incorporated into future designs.

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 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: 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: Configurations of internal components of a welder-generator are provided to improve efficiency of the cooling of the internal components. The disclosed embodiments include configurations in which a single fan, such as an engine fan, drives a single airflow path through the welder-generator. Additionally, embodiments are provided with configurations in which a primary engine fan drives a first airflow path and a secondary generator fan drives a second airflow path through the welder-generator. In disclosed embodiments, internal components are thermally aligned such that air circulates first through components with low critical operating temperatures and last through components with higher critical operating temperatures.

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 method for Magnetarc welding for metallic materials wherein at least one of the workpieces to be welded has an open cross-section. The method comprises bracing the two workpieces and moving them together, wherein the open cross-section of one workpiece is bridged by means of a metallic auxiliary part to form a conducting closed region, and after the activation of a magnetic field of a magnet coil system and of the current required for welding, the workpieces are placed with a defined spacing and an electric arc is ignited, the magnetic field of the magnet coil system sets the electric arc in rotation in order to uniformly heat the end surfaces to be welded, and subsequently, the surfaces, which are to be welded, of the workpieces are pressed against one another.

Abstract: A system, in one embodiment, includes a first service pack module and a second service pack module, wherein the first and second service pack modules are separate from one another. The first service pack module includes a hydraulic motor, an air compressor drivingly coupled to the hydraulic motor, and a generator drivingly coupled to the hydraulic motor. The second service pack module includes an engine, and a hydraulic pump drivingly coupled to the engine. The hydraulic pump also may be configured to supply hydraulic fluid to the hydraulic motor of the first service pack module. A system, in another embodiment, includes a first enclosure, a hydraulic motor, an air compressor drivingly coupled to the hydraulic motor, and a generator drivingly coupled to the hydraulic motor, wherein the hydraulic motor, the air compressor, and the generator are self-contained within the first enclosure without an engine and a hydraulic pump.

Abstract: A soundproof type engine generator has a first external air inlet and a second external air inlet formed on a soundproof case K. A first cooling passage guides external air drawn in through the first external air inlet through a duct to a first fan, then from the first fan to a generator and discharges the air out of the soundproof case K. A second cooling passage guides external air drawn in through the second external air inlet to an engine using a second fan and then discharges the air out of the soundproof case The first fan is made up of a disk-like planar part, a plurality of first blades and a plurality of second blades, respectively provided radially on both head and tail sides of the planar part. External air drawn with the plurality of first blades through the first external air inlet is guided through the duct to the generator, and discharged out of the soundproof case. Air in the soundproof case is discharged with the plurality of second blades out of the soundproof case.

Abstract: A system is provided that includes a torch power unit. The torch power unit includes a compressor and a controller configured to adjust the compressor based on a profile indicating a resonance point for the compressor. A method is also provided that includes adjusting the compressor to reduce vibrations or movement of the compressor based on a resonance point. A machine-readable medium that includes code that includes instructions to adjust a rate of velocity change based on a resonance point is also provided. A method of operation is provided that includes reducing vibrations associated with a resonance point of the device by increasing the rate of velocity change at the resonance point as compared to non-resonance regions.

Abstract: A system, in one embodiment, may include a welding generator having a rotor and a stator, an engine coupled to the generator wherein the rotor comprises a mass configured to provide a substantial amount of inertia to smooth operation of the engine. A system, in another embodiment, may include an engine and an electromechanical device coupled to the engine, wherein the electromechanical device comprises a rotor having a mass effective to absorb energy from the engine during firing portions and return energy to the engine during non-firing portions of a cycle of the engine. A method is provided for removing a flywheel that substantially provides inertia to an engine of a welding system and providing inertia to smooth operation of the engine without or independent of the flywheel. Another method is provided that includes substantially providing inertia to an engine via a rotor of a generator.

Abstract: A fueling assembly for a fuel tank positioned in an engine driven welder. The fueling assembly includes a filler tube, a fuel level monitor and a grommet. The filler tube has a bottom portion and a top portion. The bottom portion of the filler tube has a cross-sectional area that is greater that any region in the top portion of the filler tube. The fuel level monitor includes a fuel level sensor position in the fuel tank and/or filler tube. The fuel level monitor includes a fuel level indicator positioned on a side of the housing so as to enable an operator to simultaneously view the fuel level indicator and the opening used to direct fuel into the filler tube during the filling of the fuel tank. The grommet at least partially seals the tube access opening to inhibit fluids entering the interior of the housing of the engine driven welder.

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: A welding-type system and method for providing supplemental output power in an engine-driven, welding-type system. The welding-type system includes a battery, an engine, and a generator coupled to the engine to be driven to generate a power. The system also includes a power conditioning circuit configured to convert the power generated by the generator to a primary welding-type power and an output configured to deliver the welding-type power to drive a welding-type process during a first state and a second state of the welding-type process. The system further includes a controller configured to monitor the welding-type process and selectively couple the battery to the output during the second state of the welding-type process to provide a supplemental welding-type power to drive the welding-type process during the second state of the welding-type process.

Abstract: An engine driven welding machine which is favorable in operability and has high reliability and reliably performs idle stop and restart is provided.

Abstract: An electric arc engine welder housing has an opening defined by the housing and a door connected to the housing. The door has a first panel and a second panel. The second panel has a pair of members extending from opposite ends of the second panel. The members are selectively received by slots formed on opposite walls of the opening. The members slide along the slots during movement of the second panel. The housing has mounting brackets each of which has a first leg and a second leg, each having an opening therethrough. The legs are substantially perpendicular to one another. The first leg is mounted to a side wall of the cabinet, and the second leg is mounted to a support surface for the cabinet. Fastening members secure the legs to the cabinet side wall and the support surface.

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, 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, 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 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 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: 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 integrated welding system is described that includes an engine-driven power supply, control circuitry for regulating power from the power supply and for delivering power suitable for welding, and a wire feeder driven by the generated power for delivering a continuous feed of wire electrode. The system is suitable for MIG and flux core welding applications, and may further include an optional gas supply for a shielding gas. Other power is available in the system, such as for running conventional 120V and 240V power tools, lights and so forth. The unit may also be operated from an external power source, typically the power grid. The unit may be designed to permit selective operation in accordance with constant voltage and constant current regimes for MIG, TIG and stick welding.

Abstract: A low fuel shut off for a portable engine-driven welder is disclosed that disables the engine when the fuel level drops below a desired level. The system includes a controller configured to receive the current fuel level signal from a fuel sensor positioned in or near the fuel tank. The controller is connected to a maintenance display that may include a fuel gauge, a visual alarm, and an audible alarm. The controller regulates the fuel supply by actuating a valve and closing the valve when the fuel level drops below the desired level. The low fuel shut off works in conjunction with a visual and/or an audible alarm alerting the operator before and/or after the engine is disabled. The controller is configured to receive data from other engine sensors and can disable the engine if the parameters reach a specified level.

Abstract: A remote drain and filter arrangement for a portable engine-driven generator is disclosed that positions the oil filter and oil drain at a location outside the enclosure of the generator. The arrangement generally consists of an oil filter assembly and oil drain assembly. The oil filter assembly includes an oil filter adapter used to interface with the oil filter and is coupled to the engine via oil conduits. The oil drain assembly includes an oil drain conduit and a flow control device that allows the oil to be drained from a location outside of the enclosure of the generator. A pump can be used to allow for sufficiently longer oil conduits. The invention is retrofittable to current engine-driven generators and can also be incorporated into future designs.

Abstract: A method and apparatus for welding with an engine driven inverter power supply includes generating an ac output with an engine and generator. The output is rectified and inverted to provide an ac inverter output. The engine is controlled using feedback indicative of a welding output operating parameter. The feedback may also be taken from the inverter or generator, and the generator may be controlled instead of or in addition to the engine. Engine parameters that may be controlled include engine speed, selecting between an idle speed and a run speed, a throttle position, a fuel pump, an injection timer, a fuel to air ratio, fuel consumption and ignition timing. Another aspect of the invention is having the feedback be responsive to one or more of the welding current, welding voltage, welding power, or functions thereof. The feedback may be responsive to the current, voltage, power, ripple and functions thereof.

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

Abstract: A multifunction meter and method for monitoring a welding-type device is disclosed. The multifunction meter has a single display unit, a first input configured to receive feedback from an engine, and a second input configured to receive feedback from a power converter. The engine is configured to deliver power to the power converter which is configured to deliver a welding-type power to a welding-type apparatus. A processing unit is connected to the single display unit, the first input, and the second input, and processes the feedback from the engine and the feedback from the power converter and displays data indicative of engine operation and power output of the power converter on the single display unit.

Abstract: A cabinet for an engine welder including an output power module driven by a DC input signal from a rectifier having an AC input signal created by an alternator rotated by an internal combustion engine. The cabinet has a front panel with a pivotally mounted door with an open and closed position. The door is used to expose a large accessible compartment. This compartment contains major components of the welder, such as the rectifier, the power source module, the control module of the engine and a support structure for the capacitors and diodes used to control the alternator.

Abstract: An engine driven welder-type device and method of powering an accessory are disclosed. The device has an engine coupled to a power converter constructed to generate an electrical power suitable for welding applications. The device also provides a relatively uniform power to an auxiliary outlet across a wide range of engine speeds.

Abstract: A fueling assembly for a fuel tank positioned in an engine driven welder. The fueling assembly includes a filler tube, a fuel level monitor and a grommet. The filler tube has a bottom portion and a top portion. The bottom portion of the filler tube has a cross-sectional area that is greater that any region in the top portion of the filler tube. The fuel level monitor includes a fuel level sensor position in the fuel tank and/or filler tube. The fuel level monitor includes a fuel level indicator positioned on a side of the housing so as to enable an operator to simultaneously view the fuel level indicator and the opening used to direct fuel into the filler tube during the filling of the fuel tank. The grommet at least partially seals the tube access opening to inhibit fluids entering the interior of the housing of the engine driven welder.

Abstract: A method and apparatus for welding with an engine driven inverter power supply includes generating an ac output with an engine and generator. The output is rectified and inverted to provide an ac inverter output. The engine is controlled using feedback indicative of a welding output operating parameter. The feedback may also be taken from the inverter or generator, and the generator may be controlled instead of or in addition to the engine. Engine parameters that may be controlled include engine speed, selecting between an idle speed and a run speed, a throttle position, a fuel pump, an injection timer, a fuel to air ratio, fuel consumption and ignition timing. Another aspect of the invention is having the feedback be responsive to one or more of the welding current, welding voltage, welding power, or functions thereof. The feedback may be responsive to the current, voltage, power, ripple and functions thereof.

Abstract: An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and an electric compressor. An engine, an electric current generator, and an electric air compressor 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 electric air compressor can be at least partially powered by the electric current generator during the operation of the engine. Alternatively, the air compressor can be powered by an external source of power without the use of the engine/generator.

Abstract: An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and compressor. An engine, an electric current generator, and an air compressor 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. A drive connector at least partially connects the air compressor to the engine and/or electric current generator. The drive connector includes a gear box that has at least one gear.

Abstract: An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and an electric compressor. An engine, an electric current generator, and an electric air compressor 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 electric air compressor can be at least partially powered by the electric current generator during the operation of the engine. Alternatively, the air compressor can be powered by an external source of power without the use of the engine/generator.

Abstract: An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and compressor. An engine, an electric current generator, and an air compressor 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. A drive connector at least partially connects the air compressor to the engine and/or electric current generator. The drive connector includes a gear box that has at least one gear.

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 door and latch assembly for use on an electric arc engine welder is provided. The door and latch assembly includes a door mounted on an associated arc engine welder housing. The door is movable between a door open position wherein an associated opening on the associated housing is accessible and a door closed position wherein the door covers the associated opening. A latch is pivotally mounted on the door. The latch is movable between a latch closed position wherein the latch locks the door in the door closed position and a latch open position wherein the door is movable toward the door open position. A locking device is on the door. A locking device locks the latch in the latch closed position when the locking device is enabled and allows the latch to move from the latch closed position toward the latch open position when the locking device is disabled.

Abstract: An electric arc engine welder includes a housing having a cavity therein. An opening is defined by the housing and is connected to the cavity. A track member is mounted to the housing adjacent the opening. The track member defines at least one slot along a longitudinal extent thereof. Two hooks are connected to a door and are received in the at least one slot for removably mounting the door to the housing. The two hooks are spaced apart from one another a first distance. Two notches are defined in the track member and are connected to the at least one slot. The two notches are spaced apart from one another a second distance that is different than a first distance. The notches allow the door to be removed from the housing.

Abstract: A portable and fully integrated welder and compressor combination includes a housing having an engine, electrical current generating alternator, and a belt-driven screw air compressor. The engine is configured to drive the generator directly, and a pulley arrangement is provided on the engine to drive the belt-driven screw air compressor.

Abstract: A liquid and gas separator to generate a shielding gas from the exhaust gas of an internal combustion engine. The liquid and gas separator can be a separate portable component or a component that is integrated with the arc welder.

Abstract: A method and apparatus for welding with an engine driven inverter power supply includes generating an ac output with an engine and generator. The output is rectified and inverted to provide an ac inverter output. The engine is controlled using feedback indicative of a welding output operating parameter. The feedback may also be taken from the inverter or generator, and the generator may be controlled instead of or in addition to the engine. Engine parameters that may be controlled include engine speed, selecting between an idle speed and a run speed, a throttle position, a fuel pump, an injection timer, a fuel to air ratio, fuel consumption and ignition timing. Another aspect of the invention is having the feedback be responsive to one or more of the welding current, welding voltage, welding power, or functions thereof. The feedback may be responsive to the current, voltage, power, ripple and functions thereof.

Abstract: Methods and systems for cutting off the supply of fuel to an engine in response to engine turn-off. A fuel cutoff solenoid or functionally equivalent device is connected to a source of electrical power in response to detection of conditions representing engine turn-off. One method for cutting off the supply of fuel to the engine comprises the following steps: detecting whether ignition pulses are present; and then activating a device for cutting off the supply of fuel to the engine in response to detecting the cessation of ignition pulses. The fuel cutoff device is activated by connecting it to either a battery or an output of a generator being driven by the engine. In the latter case, the rotor is grounded and a bipolar transistor is bypassed in response to detection of conditions representing engine turn-off.

Abstract: An integrated welder, generator and compressor unit that includes a housing that at least partially contains components of a welder, generator and compressor. An engine, an electric current generator, and an air compressor 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. A drive connector at least partially connects the air compressor to the engine and/or electric current generator. The drive connector includes a gear box that has at least one gear.

Abstract: A hinge arrangement for a welder enclosure includes a door panel having at least one hinge at one end that is engagable in a slot of a base to allow the door panel to move between a maximum closed position to a maximum open position. The hinge and slot arrangement of the door panel and base allow the door panel to open and close through a rotation point from a maximum open position to a maximum closed position, and also allows complete removal of the door panel at certain positions between the maximum open position and the maximum closed position.

Abstract: An oil separator usable with a welder and air compressor combination unit. The oil separator includes a cylindrical housing having an inlet that receives the stream of compressed air containing oil from the air compressor. Within the oil separator, there is a deflector baffle that redirects the flow of the oil to a swirling, downwardly directed path along the inner surface of the cylindrical housing where the air is separated out therefrom and passes upwardly to exit through a fluid outlet formed in the cover of the separator. The swirling oil flows downwardly through an annular slot formed between a circular plate and the inner surface of the cylindrical housing into a lower chamber where the oil is channeled by radially directed baffles into radial channels to redirect that oil toward an oil outlet at the center of the circular bottom where that oil exits to be re-circulated in the combination unit or for disposal.

Abstract: An oil separator usable with a welder and air compressor combination unit. The oil separator includes a cylindrical housing having an inlet that receives the stream of compressed air containing oil from the air compressor. Within the oil separator, there is a deflector baffle that redirects the flow of the oil to a swirling, downwardly directed path along the inner surface of the cylindrical housing where the air is separated out therefrom and passes upwardly to exit through a fluid outlet formed in the cover of the separator. The swirling oil flows downwardly through an annular slot formed between a circular plate and the inner surface of the cylindrical housing into a lower chamber where the oil is channeled by radially directed baffles into radial channels to redirect that oil toward an oil outlet at the center of the circular bottom where that oil exits to be re-circulated in the combination unit or for disposal.