Intelligent welding system technologies: State-of-the-art review and perspectives

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 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 system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Method and system to start and use combination filler wire feed and high intensity energy source for welding

An electric arc welding apparatus comprising at least a first consumable electrode and a second consumable electrode movable in unison along a welding path between the edges of two adjacent, mutually grounded plates, a first power supply for passing a first welding current at a first low frequency between the first electrode and the two plates, a second power supply for passing a second welding current at a second low frequency between the second electrode and the two plates, where each of the power supplies includes a three phase voltage input operated at line frequency, a rectifier to convert the input voltage to a DC voltage link and a high frequency switching type inverter converting the DC voltage link to a high frequency AC current, an output rectifier circuit to provide a positive voltage terminal and a negative voltage terminal, and an output switching network operated at a given low frequency for directing a pulsating welding current at the given low frequency from the two terminals across one of the electrodes and the plates, and a circuit for independently adjusting the given low frequency so the value of the first low frequency of the first power supply is different from the second low frequency of the second power supply.

Tandem electrode welder and method of welding with two electrodes

An electric arc welder for performing a pulse welding process by a current between an advancing electrode and workpiece where the welder comprises a short detecting circuit for creating a short signal upon occurrence of a short circuit between the advancing electrode and the workpiece and a boost circuit to create a plasma boost pulse after the short circuit is cleared during the time period when the welder is not outputting the peak pulse current

Pulse welder and method of using same

Nonlinear adaptive welders and power source controls are provided along with welding methods method for regulating a welding process, in which one or more welding waveform parameters are adapted in nonlinear fashion based on measured welding process feedback information.

Non-linear adaptive control system and method for welding

A control system for an electric arc welder performing a welding process between an electrode and a workpiece, which system comprises: a high speed switching type power supply with a controller operated at a switching frequency of at least about 10 kHz with an input current control signal to adjust the output current of the power supply; a first sensor sensing the actual arc voltage; a second sensor sensing the actual arc current; a first circuit for creating a power signal representing the desired real time power level at progressive times during the welding process; a second circuit for creating a function of the sensed actual voltage and the sensed actual current; and a third circuit for adjusting the current control signal in accordance with the difference between the power signal and the function of the actual voltage and current, preferably arc power.

System and method for controlling an electric arc welder

An electric arc device and methods to build up, clad, join, or overlay an alloyed metal onto a parent metal with minimal admixture. The methods employed in the electric arc device provide a high frequency waveform with a high amplitude pulse, a low amplitude background current, and a special shorting routine, to alleviate the problem of generating too much ad-mixture. A fast transition from a peak current level to a background current level along with a shorting response and a plasma boost pulse reduces the droplet size and reduces the heat input required to achieve good welding performance.

Steven R. Peters

Papers

Tandem electrode welder and method of welding with two electrodes

Pulse welder and method of using same

Non-linear adaptive control system and method for welding

System and method for controlling an electric arc welder

Method and device to build-up, clad, or hard-face with minimal admixture