A system and method to make a welder aware of contact tip-to-work distance (CTWD) during a welding process. One or both of welding output current and wire feed speed is sampled in real time during the welding process. The actual CTWD is determined in real time based on at least one or both of the sampled welding output current and wire feed speed. The actual CTWD may be compared to a target CTWD in real time, where the target CTWD represents an estimated or desired CTWD for the welding process. A deviation parameter may be generated based on the comparing. An indication of the deviation parameter or the actual CTWD may be provided to a welder performing the welding process as feedback, allowing the welder to adjust the actual CTWD to better match the target CTWD in real time during the welding process.

Systems and methods providing contact tip to work distance (ctwd) feedback for augmented reality

Disclosed is a wire feeder (1) including a housing (2) having wire inlet (6) and outlet (8) regions. In some approaches, a tensioning assembly (4) includes a pivotable tension arm (14) and a pivotable tension knob assembly (32). The pivotable tension arm (14) has a pivot axis oriented perpendicular to the direction of a wire (W) fed through the wire feeder (1), while the pivotable tension knob assembly (32) has a pivot axis oriented parallel to the direction of the wire (W) fed through the wire feeder (1). A roller assembly (10) includes a drive roller (18) rotatably coupled to the pivotable tension arm (14), and a feed roller (30) coupled to the housing (2). The feed roller (2) is positionable opposite the drive roller (18) to receive a welding wire therebetween and to move the welding wire from the wire inlet region (6) to the wire outlet region (8). A gear assembly (66) transmits rotational motion from a motor (12) to the feed roller (30).

Multifunction wire feeder for a portable welding system

A welding wire conveyor roller for conveying a welding wire includes a receiving aperture for receiving a receiving pin, and a running surface for the welding wire, and a feeding device for conveying a welding wire includes a drive motor, at least two receiving pins arranged at a distance to each other, and at least two welding wire conveyor rollers with running surfaces for the welding wire which are placed upon the receiving pins by appropriate receiving apertures. For achieving improved conveying properties even with different welding wires, an area elastically deformable in the radial direction is arranged between the running surface and the receiving aperture of the welding wire conveyor rollers.

Welding wire conveyor roller and feeding device for conveying welding wire

The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch, and a sensor, in which the sensor is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor. The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

Electrode diameter sensing consumables

A feed roller rotation measurement system includes a voltage tuned oscillator (VTO) having a capacitor and an inductor coupled to each other. The VTO is configured to be disposed adjacent a shaped feature formed in a surface of a feed roller of a wire feeder. The feed roller rotation measurement system also includes a phase locked loop (PLL) controller electrically coupled to the VTO and configured to determine and send a correction voltage to the VTO to maintain the VTO at a desired oscillating frequency. The feed roller rotation measurement system further includes a processor coupled to the PLL controller and configured to receive a signal from the PLL controller indicative of the correction voltage and to calculate a speed of rotation of the feed roller based at least in part on the received signal.

System and method for measuring rotation of a wire feed mechanism

A welding system includes a welding wire feeder (20), a welding power supply (16), and a sensor (38). The power supply (16) is coupled to the welding wire feeder (20) and configured to produce a welding arc (12). The sensor (38) is configured to sense a parameter indicative of a size of a welding wire (24) fed through the welding wire feeder. The sensor (38) is configured to send a signal to the power supply (16), the signal representing the parameter indicative of the size of the welding wire (24). The power supply is configured to automatically implement at least one of an arc starting parameter or a welding parameter based on the signal.

System and method for determining welding wire diameter

Devices and methods for indicating power on a torch. In one example, a welding or plasma cutting torch includes an indicator coupled to the torch. The torch also includes control circuitry coupled to the indicator and configured to provide a first signal and a second signal to the indicator. The indicator is configured to receive the first signal when at least one of welding power and arc starting power from a power supply is available at the torch and to receive the second signal when the at least one of active welding power and the arc starting power from the power supply is not available at the torch.

Devices and methods for indicating power on a torch

The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch (10), and a sensor (31), in which the sensor (31) is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor (31). The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

Welding system and method with a sensor for sensing a parameter indicative of the diameter of a welding consumable

Provided are devices and methods for indicating power on a welding torch. In one example, a welding or plasma cutting torch includes an indicator coupled to the torch. The torch also includes controlcircuitry coupled to the indicator and configured to provide a first signal and a second signal to the indicator. The indicator is configured to receive the first signal when at least one of welding power and arc starting power from a power supply is available at the torch and to receive the second signal when the at least one of active welding power and the arc starting power from the power supply is not available at the welding torch.

Bradley William Hemmert

Papers

System and method for determining welding wire diameter

Devices and methods for indicating power on a torch

Electrode diameter sensing consumables

Welding system and method with a sensor for sensing a parameter indicative of the diameter of a welding consumable

Devices and methods for indicating power on a welding torch