A welding system including an arc monitoring, training, and control system is disclosed. The welding system includes a power supply, controller, and associated memory. When a weld is performed, the weld command and weld feedback parameters can be stored in the memory, along with associated alarm limit values. During subsequent welds, the input weld commands and actual feedback values can be compared to the established limits, and a fault signal provided to an operator or supervisor when the value exceeds the established limits. The fault signals can be used for training operators, as well as providing monitoring signals, and can be stored with weld data in a database for later analysis. In addition, collected weld data can be used to determine when to clean, repair, or replace consumables, including, for example, contact tips, wire drive liners, and drive rolls, and to monitor usage of wire and gas.

Automatic weld arc monitoring system

A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal, a network of switches switched at a high frequency with a given duty cycle to convert the input into a first internal AC signal, an isolation transformer with a primary winding driven by the first internal high frequency AC signal and a secondary winding for creating a second internal high frequency AC signal and a rectifier to convert the second internal AC signal into a second DC output signal of the second stage, with a magnitude related to the duty cycle of the switches; and, a third stage to convert the second DC output signal to a welding output for welding wherein the input stage has a regulated DC to DC converter with a boost power switch having an active soft switching circuit.

Three stage power source for electric ARC welding

A host and a storage system each keep a shared identifier indicating a state of a system. The storage system acquires, at update of data, a data pair including data for a change through processing of the host and data before the update. The storage system relates the data pair to a shared identifier. When the host indicates an identifier, the storage system restores data using the data pair.

Data restoring method and an apparatus using journal data and an identification information

A real-time virtual reality welding system including a programmable processor- based subsystem, a spatial tracker operatively connected to the programmable processor- based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of displaying the simulated weld puddle on the display device in real-time.

System and method providing arc welding training in a real-time simulated virtual reality environment using real-time weld puddle feedback

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.

System for tracking and analyzing welding activity

A method and apparatus for welding include initiating a pulse welding process includes initiating a welding arc by providing CC type welding power, maintaining the arc by providing CV type power. Then, pulse type welding power is provided. The method and system can be used to start short circuit, or other welding processes by providing short circuit power, or welding power of a given mode, instead of providing pulse power. Also, in one alternative, a method and system of initiating a pulse, short circuit, or given welding process includes initiating a welding arc by providing CC type welding power at least until a pseudo-equilibrium for the arc is established. Then, providing welding power in a pulse, short circuit, or the given mode.

Method and apparatus for welding

A method and apparatus for feeding wire in a welding system include one or more motors disposed adjacent the wire to drive it. A wire feed motor is also disposed along the wire path, and is closer to the source of wire than the torch, and closer to the source than the one or more motors. The motors may be a pair motors disposed on opposite sides of the wire and move the wire to and away from an arc end of a torch. They preferably reversing the direction of the wire within one process cycle. The or more motors may be a stepper motor, a servo motor, a zero backlash motor, a gearless motor, a planetary drive motor, or a linear actuator (such as a piston), in various embodiments.

Method and apparatus for feeding wire to a welding arc

A welding system includes a first sensor associated with a welding helmet and configured to sense a parameter indicative of a position of a welding torch relative to the welding helmet. The travel speed sensing system also includes a processing system communicatively coupled to the first sensor and configured to determine a position of the welding torch relative to a workpiece based on the sensed first parameter.

Helmet-integrated weld travel speed sensing system and method

A method and apparatus for controlling a welding-type power supply includes providing a current wave form having an arc current portion and a short circuit current portion. An arc state is entered by retracting a welding wire, and a short circuit state is entered by advancing the wire. The current enters the arc current portion prior to the creation of the arc and the current enters the short circuit current portion prior to the creation of the short, by coordinating the wave form with the wire retraction. This may be preformed on a wire having a diameter of 2.4 mm or more to a weld and applying a welding current of less than 100 amps, or of less than 35 amps. One current waveform during the arc state includes at least three segments, and the last segment is entered into prior to the short circuit state being entered, and is the same current magnitude as the current magnitude at the start of the short circuit state. Penetration and/or bead formation may be controlled by controlling the advancement of the wire into the weld pool. The balance may be user set.

Method and apparatus for controlling a welding system

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

Richard M. Hutchison

Papers

Method and apparatus for welding

Method and apparatus for feeding wire to a welding arc

Helmet-integrated weld travel speed sensing system and method

Method and apparatus for controlling a welding system

Welding electrode stickout monitoring and control