Abstract: A controller for a welding system adapted to determine a value of a weld secondary parameter across a weld secondary component based on a sensed parameter is provided. The controller may also be adapted to compare the determined value to a reference value range and to alert a user to a presence and location of a weld secondary error when the determined value is outside the referenced value range.

Abstract: Plasma cutter and welder units are provided for fabricating a pipe. The plasma cutter and welder unit include a support structure having a carriage rotatably supported thereon. A plasma cutter nozzle and a weld nozzle are mounted to the carriage. A drive mechanism adjusts positioning of the plasma cutter and weld nozzles through varying control by a controller during operation. Additionally, a bearing support is provided for cradling the pipe during fabrication. The bearing support includes a plurality of bearing plates. A wedge structure is secured to each of the bearing plates and to a fixture base to form a nest for receiving the pipe. An isolation pad is disposed between the wedge structure and the fixture base.

Abstract: A wire drive system includes a wire feed motor for feeding welding wire in a continuous welding process. The wire drive system further includes a controller connected to the wire feed motor for driving the motor responsive to a command signal. The controller is capable of detecting the source of power from which the wire feed motor is driven wherein a first possible source of power is taken from the welding arc and wherein a second possible source of power is taken from the welding power supply.

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 welding machine that includes a machine frame having an opening permitting access to an interchangeable tooling module installed on the machine. The welding machine includes one or more light curtains covering the opening to disable operation of one or more welding stations on the tooling module if the light curtain is breached by an operator, robot, or other object. The welding machine includes a selector arm attached to the machine frame at a location between a first end and a second end of the opening. The selector arm can be moved into and out of position at the opening to selectively define either a single light curtain across the opening or a pair of adjacent light curtains that permit separate operation and access to separate welding stations behind each of the two light curtains.

Abstract: An object of the present invention is to reduce the size of an entire device by simplifying a device configuration, and also accurately measure the stroke position of a rod. A lower electrode 2 is mounted on an upper portion of an electrode holder tube 3. A rod 4 that is vertically movable within the electrode holder tube 3 is divided into a first rod 4a and a second rod 4b. The rod 4 is urged upward by a compressed spring 5 that is interposed between a spring receiving seat 14 fixed to the upper end surface of the second rod 4b and an insulating adapter 7. Pressurized air supplied from a pressurized air supply pipe 15 to assist the urging force is received by a pressure receiving portion on the lower surface of the spring receiving seat 14, thereby assisting the spring 5 to urge the rod 4 upward. A magnetic sensor 10 is disposed below the second rod 4b, and a lower end portion of the second rod 4b is directly connected to a detector 17 of the magnetic sensor 10.

Abstract: The present invention relates to a welding booth that has a small foot print and can be joined to other booths for maximization of floor space use.

Abstract: A modified phase shift scheme that provides the minimum on-time and regulation benefits of the conventional phase shift method with the reduced circulating current benefits of the traditional PWM control. A welding machine comprises an inverter operatively connected to a controller, wherein the controller controls a welding process of the welding machine using modified phase shifted switching of the inverter.

Abstract: A welding apparatus having a waveform compensation device, a power section coupled to the waveform compensation device which generates a welding waveform in accordance with a signal from the waveform compensation device, and a frequency detection device which detects at least one of a voltage, current and power of a welding arc and determines a shorting frequency of the arc. The waveform compensation device adjusts at least a portion of the welding waveform based on an output from the frequency detection device.

Abstract: It comprises cylindrical feeder collet (6) formed with a slit portion at a front end thereof for feeding power to a welding wire internally set through; collet case (7) for storing feeder collet (6) therein, having an abutment on which the end of feeder collet (6) is abutted; flexible inner tube (4) for leading the welding wire to feeder collet (6); torch body (3) with inner tube (4) inserted therein and collet case (7) detachably disposed at the front end thereof; and spring (5) for pressurizing feeder collet (6) toward the front end of the welding wire, wherein there is provided a taper surface on at least any one of the front end of feeder collet (6) and the abutment of collet case (7). Thus, it is structurally simple and applicable for a curved torch.

Abstract: A cold metal transfer (CMT) contact tip has a substantially copper-free contact surface defining a wire passage. The CMT contact tip is used with a CMT welding apparatus having a weld wire and a wire feeder for feeding and oscillating the weld wire forward and backward through the wire passage where the weld wire shares a concentric axis with the wire passage.

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

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: In one embodiment, a holding fixture is disclosed for locating and stabilizing substantially identical repeated units during joining of the repeated units. In another embodiment, a method is disclosed for manufacturing a structure comprising substantially identical repeated units. In still another embodiment, a welded structure is provided comprising a plurality of welded together substantially identical repeated units.

Abstract: A pressure welding method is provided and a pressure welding machine (1) is provided with a frame (10), two welding heads (13, 14), mobile along a feed axis (41), and two adjusting units (17, 18). The adjusting units (17, 18) include feed drives (23) for the welding heads (13, 14). The two adjusting units (17, 18) are mounted so as to be axially movable (41) on the frame (10) and are interlinked with an adjusting drive (25) by means of a common adjusting element (26) and supported in a closed system of forces while receiving the pressure welding forces, thereby relieving the frame (10). The common adjusting element (26) is configured as a continuous spindle (27) having two self-locking threads (28, 29) that run in opposite directions.

Abstract: A welding observation apparatus is provided to use partial darkening by a telecentric optical system and a photochromic filter (PCF) as an optical system for filtering light emission from arc discharge in order to verify the welding condition under the welding arc discharge, without forming an image on the PCF, so that light reducing performance can be secured even if a focus shifts from on the PCF, with satisfactory monitoring of welding condition. The welding observation apparatus comprises: an arc welding unit 8; an objective optical system (1, 2) for concentrating light from the arc welding unit 8; a telecentric optical system 3 for guiding the light concentrated by the objective optical system (1, 2); a PCF 4 for illuminating with the light guided by the telecentric optical system 3; and a solid state imaging device 9 for receiving the light passing through the PCF 4, wherein the light from the arc welding unit 8 is partial-darkened by the PCF 4.

Abstract: Welding equipment includes a torch for irradiating a laser beam, wire feeding means for feeding a filler wire, and tracking means for controlling the moving tracks of the torch and the wire feeding means so as to make the moving tracks follow a welding line. The tracking means has a contactor provided so as to be advanceable/retractable for making contact with a joint object resiliently. The torch and the wire feeding means are moved so as to follow the welding line by touching the contactor of the tracking means resiliently to the joint object while feeding the filler wire to a welding portion and irradiating that portion with the laser beam, thereby joining the joint objects.

Abstract: A welding control apparatus according to the present invention includes an integrator for starting calculation of a voltage error integral value Sv2, expressed by a formula (1) given below, from a time when a first pulse period ends and a second pulse period starts in a pulse cycle, based on various data of information regarding a gradient Ks of an external characteristic of a welding power supply and a welding current setting value Is2 and a welding voltage setting value Vs2 both in a second pulse period, which are preset as parameters in the formula (1), as well as on an instantaneous value Io2 of a welding current and an instantaneous value Vo2 of a welding voltage both detected in the second pulse period, a comparator for comparatively determining whether a value of the voltage error integral value Sv2 provided as the calculation result has become 0, and a waveform generator for, per pulse cycle, terminating the relevant pulse cycle and starting a next pulse cycle at a time when the value of the voltage e

Abstract: A system that facilitates dynamic configuration of a welding system with respect to a sensor comprises a processing unit associated with the welding system. A configuration component facilitates configuring the welding system with respect to the sensor upon determining that the sensor is coupled to a local bus associated with the processing unit. A remote access component can facilitate remotely accessing the welding system, the configuration of the welding system alterable by way of the remote access component.

Abstract: An inert gas welding torch comprising; a torch body, a collet, an electrode, a nozzle, the nozzle having an upper and lower end, the upper end of the nozzle being connected to the torch body, the collet connected to the torch body and the electrode connected to the collet with the electrode extending through and out the lower end of the nozzle, a path for inert gas starting from a gas supply line and passing through the torch body to the upper end of the nozzle, the gas then passing through at least three gas portals with the gas portals having an inlet and an outlet, the inlet being located at the upper end of the nozzle and the outlet toward the lower end of the nozzle, the portals having substantially uniform dimensions from the inlet to the outlet, wherein the length of the gas portal is at least as long as the longest line that can be drawn across the area of the gas portal inlet.

Abstract: Methods and systems for clearing short circuits during a MIG welding process are disclosed. A method may include detecting a short circuit and increasing output current of a power source at a first ramp rate to clear the short circuit. The method further includes increasing output current at a second ramp rate after the output current reaches a threshold. Power sources and systems implementing the method are also provided.

Abstract: A device for at least partially drying the outer coating on a stick electrode in the form of a generally straight center welding wire of magnetic metal with an axis and surrounded by an extruded pliant mass with a settable binder. The device comprises a conveyor to transport a succession of the electrodes along a given path, a multi-turn induction heating coil extending along the path and spaced from the moving electrodes and a power source for passing an alternating current through the coil to induce an alternating voltage difference in the wire to cause AC current flow in the wire to heat the wire.

Abstract: A robotic end effector system and method having a plurality of end effectors which are selectively suitable for particular applications on a workpiece. The end effectors include a resident controller adapted to execute tasks specific to the end effector and are rapidly attachable and removable from the robot for easy change over to different workpieces.

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

Abstract: This invention relates to a welding carriage operable to drive across a surface of a work piece having a joint to be welded. The welding carriage comprises a number of wheels, where each wheel is pivotal around an axle and where each wheel is a magnetic wheel; the welding carriage further comprises means for supporting a welding device wherein at least one of the wheels can be flexed inwardly or outwardly so that the welding carriage can travel over curved surfaces. The welding carriage can travel over magnetizable surfaces having any direction, e.g. orientation in space. The welding carriage can carry a laser sensor arrangement arranged to detect the position as well as the direction of a joint to be welded, so that the welding carriage is applicable for performing fully automated welding.

Abstract: A system and method for welding spliced vertical box columns with an electroslag welding system. The system includes a welding fixture having opposing, paired and positionally adjustable welding shoes, run-off tabs, and sumps affixed at the junction of box columns to be spliced. A distributed control electroslag welding system, articulating boom, welding torch and consumable guide tube oscillator feed provide molten flux within the shoes filling from the sump to the run-off tab.

Abstract: A welding apparatus is provided for carrying a welding gun across or past a surface for making welds. The apparatus may include one or more rolling components, such as wheels for example, that do not substantially plastically deform as a result of contacting or being in close proximity to recently completed welds or preheated joints and provide adequate traction to move the apparatus across or past the surface. A portion of the contact surface of the rolling component may be configured with a given surface roughness to provide sufficient traction.

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: A contact fitting for a welding apparatus includes a housing, and first contact device, a second contact device, and a third contact device arranged between the first and second contact devices. The third contact device is movable relative to the first and second contact devices. The first contact device has an elongated form, is fixedly arranged in the housing, and extends from a first end, which is arranged between first and second ends of the housing, to a second end. The second contact device has an elongated form, is suspended spring-loaded to the housing, and extends from a first end, which is arranged between the first and second ends of the housing, to a second end.

Abstract: A method of consumable electrode type gas shield arc welding characterized in that a shield gas consisting of an inert gas is fed toward a consumable electrode and an addition gas consisting of a mixture of oxidizing gas and inert gas toward an outer edge of welding pool. Further, there is provided a welding torch for use in the method. Thus, in the welding of steel material in accordance with GMA welding technique, the dissolved oxygen concentration of the weld metal can be reduced to 100 ppm or less, and while maintaining arc stability, desirable bead formation can be attained.

Abstract: A welding device includes a welding torch, a memory, a power supply, an input section, a selector, and a controller. The welding torch includes a welding tip having a feeder for supplying electric power to a welding wire. The memory stores a plurality of welding conditions in which a feeder-work-piece to be welded distance is associated with at least one a length of the wire supplied per unit time, a weight of the wire supplied per unit time, and a set electric current. The power supply supplies electric power between the wire and the work-piece. The input section receives an input of a set value of a feeder-work-piece distance. The selector selects one of the welding conditions stored in the memory based on the set value. The controller controls the power supply based on the welding condition selected by the selector.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains lithium aluminate in either the flux or the electrode portion of the electrode.

Abstract: A duty cycle controller having a processor configured to control a welding-type apparatus is disclosed. In one embodiment, the processor may be configured to control the welding-type apparatus according to a variable maximum duty cycle to substantially delay entry into a thermal shutdown mode of the welding-type apparatus based on at least one operating condition. Various additional devices and methods are also disclosed.

Abstract: Methods for arc welding unalloyed or low-alloy steels with consumable electrode under protective gas are suggested, in which the protective gas is a mixture comprising at least helium and an active gas as well as a further inert gas. In the general case, the proportion of the active gas in the total volume of the protective gas is to be in the range from more than 0.5% to approximately 1,5% and the proportion of helium in the total volume of the protective gas is to be more than 30%. In case an electrode having a lowered or medium Si content of approximately 0.2% to approximately 0.4% is used, the proportion of the active gas in the total volume of the protective gas is to be approximately 1% to approximately 5%. If an electrode with a low Si content of approximately 0.05% to approximately 0.1% is used, the proportion of the active gas in the total volume of the protective gas is to be approximately 3% to approximately 10%.

Abstract: The invention relates to a method for permanently interconnecting components from a heat-meltable metal material, using a robot-controlled welding unit for carrying out a hybrid welding process. According to the method, a high performance metal active gas welding process (high performance MAG) is carried out. A component (8) carrying out the high performance MAG welding process is carried along by the robot-controlled welding unit (2) to carry out the hybrid welding process, the GSMAW torch (3) which contributes to the hybrid welding process being guided so as to be dragged by the welding unit.

Abstract: Embodiments of methods and apparatus for welding are provided. According to one embodiment, an apparatus may include a torch body supporting an electrode at least partially extending from the torch body, the electrode having a longitudinal central axis therethrough. The apparatus may also include a heat transfer block spaced apart from the electrode and at least partially intersecting the longitudinal central axis. An electric arc may be generated between the electrode and the heat transfer block.

Abstract: One embodiment of a welding rod expander assembly for expanding a welding rod to a remote location. The welding rod expander assembly may include a first attachment member, a second attachment member, at least one elongated member and a welding rod holder. The second attachment member may be pivotally carried by the first attachment member. Further the at least one elongated member may have an external threaded end portion and a connecting end portion. The welding rod holder may be carried by the second attachment member. The welding rod holder may include a holding unit carried by the second internal threaded portion. The holding unit may be capable of receiving the welding rod. The welding rod holder may further include a clamping unit disposed on the second internal threaded portion. Further, the welding rod secured in the holding unit may be capable of expanding to the remote location.

Abstract: A method and apparatus for welding includes one or more of a welding type power source, a feedback circuit, a wire feeder and a controller. The controller preferably has an eta control circuit responsive to the feedback.

Abstract: A method for welding an edge of a first member to a side surface of a second member is provided. The first member and the second member are joined to one another at a joint. The method includes beveling an edge of the first member. The method also includes positioning the edge of the first member proximate the side surface of the second member. The method further includes supplying welding material via a welding wire along the edge of the first member to create a joint between the first and second members. Supplying welding material includes controlling a feed rate of the welding wire, such that a weld bead formed at the joint defines a concave cross-section.

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: Systems and methods are disclosed that facilitate inducing one or more actions, such as generation of a shift report data related to construction device(s), via detection of specified triggering events. The system comprises a triggering component that determines whether a triggering event has occurred a control component that initiates an action in response to the triggering event. Triggering events can comprise specific times of day as determined by a real-time clock that can be associated with a construction/fabrication device, such as a welder. Additionally, actions responsive to triggering events can be tagged for human approval prior to initiation in order to provide system flexibility.

Abstract: A robot cell comprises a support having a top surface within a plane and configured to rotate about a central axis substantially normal to the plane and a plurality of welding tables including a first welding table and a second welding table. The first welding table is operably connected to the support and configured to rotate about a first axis substantially parallel to the plane and about a second axis substantially normal to the plane. The first welding table is configured such that the second axis remains substantially normal to the plane while the first welding table rotates about the first axis. The second welding table is operably connected to the support and configured to rotate about a third axis substantially parallel to the plane and about a fourth axis substantially normal to the plane. The second welding table is configured such that the fourth axis remains substantially' normal to the plane while the second welding table rotates about the third axis.

Abstract: A welding control unit has a common power section for detecting contact of a welding material and for welding. A material contact detector for detecting contact of the welding material and a workpiece, and a power controller are built in the welding control unit. This stabilizes a bead shape in starting welding. The number of components can also be reduced, resulting in more inexpensive equipment. In addition, only a space for installing the welding control unit is needed without any additional space.

Abstract: A method and apparatus for MIG-MIG welding includes at least first and second sources (104,114) of wire, and first and second sources of power (102,112). The first source of wire provides a first wire (106) to a main arc between the first wire (106) and a workpiece (110). The first source of power (102) provides MIG power to a first current path including the first wire (106) and the workpiece (110). The second source of wire provides a second wire to a filler arc between the first wire (106) and the second wire (116). The second source of power (112) provides MIG power to a second current path including the first wire (106) and the second wire (116).

Abstract: A consumable electrode gas shield arc welding torch (20) includes a torch body (21), a tip body (22) mounted to a front end of the torch body, a tip holder (23) mounted to a front end of the tip body, a spring (26) provided in the tip body (22) in contact with the front end of the torch body (21), a pressing shaft (27) provided in the tip body (22) in contact with a front end of the spring 26) and a power feed tip (28) pressed by the pressing shaft (27) and the tip holder (23). The tip (28) includes a side surface having a projection contacting with a base end (23a) of the holder (23), with a space (29) defined between an inner surface of the holder (23) and a front end (28a) of the tip (28) when the front end (28a) of the tip (28) is inserted into the holder (23).

Abstract: An arc welding robot having a welding wire conduit which has a bend radius above a certain level and arranged so that disadvantageous stress is not applied to the conduit by the motion of the robot arm. A conduit for a welding wire is inserted through a hole of a robot pedestal from the rear side of the robot, is supported by a second support member arranged on the pedestal, extends near the front side of a rotating body of the robot, and is supported by a first support member on the upper part of the rotating body while having a required minimum bend radius. The conduit after passing through the first support member is introduced to the rear side of the upper arm and is connected to a connector at the rear side of a wire feeder while having the required minimum radius, whereby the conduit presents a generally S-shape.

Abstract: An arrangement of parts having a first part in the form of sheet metal which is in contact with the second part along an edge and is fixedly connected to the second part via at least one weld. To reduce stress peaks at the ends of welds, the first part has a slot in a section adjacent to the respective end of the weld, the slot beginning at the edge and extending to its end with a curved profile a curve bent by at least 180° up to its end.

Abstract: A gooseneck locking mechanism for a robotic GMAW torch having a torch body and a gooseneck includes a connector receiver disposed in the torch body. The connector receiver includes longitudinal ends and a passageway extending between the longitudinal ends. An indexing feature is disposed in the passageway. An elongated connector is mountable on a proximal end of the gooseneck. The connector includes a cooperable indexing feature. The locking mechanism further includes a detent for joining the connector receiver and the elongated connector. The indexing features align the gooseneck relative to the torch body, and the detent secures the connector in the connector receiver for quick release. The locking mechanism may include a plurality of electrical contacts in the connector receiver that are engageable with the connector to provide flow of electrical current through the connector receiver to the gooseneck.

Abstract: A method and a system for forming a root pass weld for a root pipe joint. A substantially periodic electric welding waveform is generated and a series of electric arc pulses are generated between an advancing welding electrode and a root pipe joint in response to the electric welding waveform. The electric welding waveform includes a base cycle having a background current phase providing a background current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and at least one heat-increasing current pulse during the background current phase providing a heat-increasing current level being above the background current level.