The invention described herein generally pertains to a system and method for evaluating one or more conditions or preliminary weld condition related to a welding system and/or method that utilizes a welding sequence to perform two or more welds with respective welding schedules. In an embodiment, an operator registration is provided that verifies the operator and identifies welding sequences to which the operator is authorized to perform. In another embodiment, one or more fixture locations are monitored to determine whether a workpiece is accurately configured prior to a welding operation. In still another embodiment, locations on a workpiece can be displayed to assist an operator in performing two or more welds utilizing a welding sequence. Moreover, a wireless system communications a data signal to a welding work cell in which such data is used to identify a welding sequence.

System and method of receiving or using data from external sources for a welding sequence

Stickout of a welding electrode wire from a welding torch is determined during welding, and based upon a welding parameter, such as welding current Different relationships are used for the determination depending upon whether the welding wire is in a short-circuit condition or an arc condition The stickout may be converted to a standardized unit of measure to make it readily understandable to an operator The stickout may be logged and associated with other parameters and information, such as workpiece, operator, welding system, date and time The stickout may be used as the basis for an alarm or a disabling operation Moreover, the stickout may be provided on a readout for the operator It may also be used as a basis for controlling a wire feeding apparatus that retracts the welding wire to a desired stickout following a weld

Welding electrode stickout monitoring and control

A welding method includes feeding a welding electrode axially from a welding torch, moving the welding electrode radially in a desired pattern with respect to a central axis of the welding torch by a motion control assembly within the welding torch, transmitting from control circuitry a signal corresponding to a position of the welding electrode relative to a weld joint or weld pool, advancing the welding torch or a workpiece to establish a weld, and transferring material from the welding electrode to a first location in an area of the weld pool. The welding electrode moves radially while feeding the welding electrode from the welding torch, the material from the welding electrode is transferred to the first location during a first cycle of the desired pattern, and the first location is controlled based at least in part on the signal.

Synchronized rotating arc welding method and system

A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer.

Systems and methods providing location feedback for additive manufacturing

The invention described herein generally pertains to a system and method for welder system that relates to creating a welding sequence for a welding environment in which the welding sequence is based upon real time data collected from a performed or previously performed welding procedure. Welding procedure information is collected and utilized to create a welding sequence to perform two or more welds in which at least one parameter is based on the collected welding procedure information (e.g., real world welding procedure).

System and method for creating or modifying a welding sequence

A method providing a welding apparatus configured to supply a welding wire to a welding gun and a welding system implementing the same is described. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program, the program dynamically adjusting the amount of welding wire retraction based at least upon one of the following: welding arc current, welding wire size, welding wire speed and burnback time. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire preferably does not extend (or minimally extends—or may be at least partially recessed within the tip) from the opening of the welding gun nozzle tip.

Welding apparatus with automated welding wire retraction

A method providing a manual welding apparatus configured to supply a welding wire to a welding gun. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire does not extend from the opening of the welding gun.

Manual welding apparatus having an automatic wire retract method

A method providing a manual welding apparatus configured to supply a welding wire (136) to a welding gun (130). The welding gun (130) has a trigger (134) and an opening where the welding wire (136) extends when the trigger (134) is activated. The method also has a computer with a user interface that includes an automatic wire retract program. The program monitors the welding gun (130) and determines when the trigger (134) is disabled. The program indicates when a first condition is satisfied and retracts the welding wire (136) so the welding wire (136) does not extend from the opening of the welding gun (130).

Manual welding methods for providing to a manual welding apparatus an automatic wire retract method

A method for providing a manual welding apparatus is provided. The manual welding apparatus is configured to supply a welding wire (136) to a welding gun (130). The welding gun (130) has a trigger (134) and an opening where the welding wire (136) extends when the trigger (134) is activated. The method also has a computer with a user interface that includes an automatic wire retract program. The program monitors the welding gun (130) and determines when the trigger (134) is disabled. The program indicates when a first condition is satisfied and retracts the welding wire (136) so that the welding wire (136) does not extend from the opening of the welding gun (130).

David Kempert

Papers

Welding apparatus with automated welding wire retraction

Manual welding apparatus having an automatic wire retract method

Manual welding methods for providing to a manual welding apparatus an automatic wire retract method

Manual welding methods for providing an automatic wire retract method for a manual welding apparatus