A welding system includes a power supply configured to output a series of welding waveforms for generating a welding current in a consumable welding electrode, and a wire feeder that advances the electrode toward a weld puddle during a welding operation. The wire feeder includes a subcircuit having a switching device and parallel resistance, the subcircuit being connected in series with the electrode such that the welding current flows through the subcircuit. The switching device is controllable between conducting and nonconducting states. The wire feeder includes a controller operatively connected to the switching device that controls switching operations of the switching device. The power supply is configured to remotely identify occurrences of the switching operations in the wire feeder and control the welding waveforms based on the occurrences of the switching operations.

A method is provided for controlling a neck detection for a welding power supply. The neck detection can be suitably performed even if the welding power supply is combined with another power supply for performing a simultaneous arc welding operation at a plurality of locations of a workpiece. The method includes using a control target welding power supply together with another power supply for performing arc welding concurrently at a plurality of locations of a common workpiece, detecting a neck in a molten portion of a welding wire which is brought into short-circuiting contact with the common workpiece, reducing the welding current for forming an arc, and automatically adjusting a neck detection value.

Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

A method for preparing an automated welding method for a welding process moves a welding torch with a consumable welding wire during a movement phase at a positioning speed from an actual to a desired start position of a welding seam, and bridges the distance of the welding wire end from the workpiece during a creep phase. The creep phase is at least partially carried out during the movement phase. The wire is moved toward the workpiece at a first specified forward feed speed until a first wire end-workpiece contact is detected, moved away from the workpiece after first contact detection and then recurrently moved away from the workpiece, and the contact is interrupted again upon detection of further contacts, and the movement of the welding wire towards the workpiece and movement away from the workpiece after the contact is repeated until the start position is reached.

A welding system includes a feeder that advances a self-shielded flux-cored welding electrode toward a weld puddle. A power supply provides a welding output to the electrode to generate an arc, and a controller controls the welding output. The controller controls the power supply to provide a background welding output to the electrode before a shorting event between the electrode and a workpiece is detected. The controller monitors the welding output to detect both the shorting event and the clearance thereof. Upon detecting clearance of the short, the controller automatically switches the welding output to a minimum magnitude fixed current welding output. After the predetermined duration, the controller automatically switches the welding output from the minimum magnitude fixed current welding output back to the background welding output until another shorting event is detected.

A welding system includes a feeder that advances a self-shielded flux-cored welding electrode toward a weld puddle. A power supply provides a welding output to the electrode to generate an arc, and a controller controls the welding output. The controller controls the power supply to provide a background welding output to the electrode before a shorting event between the electrode and a workpiece is detected. The controller monitors the welding output to detect both the shorting event and the clearance thereof. Upon detecting clearance of the short, the controller automatically switches the welding output to a minimum magnitude fixed current welding output. After the predetermined duration, the controller automatically switches the welding output from the minimum magnitude fixed current welding output back to the background welding output until another shorting event is detected.

Systems and methods for selecting a welding output waveform based on characterizing a welding circuit output path with respect to its electrical characteristics. At least one electrical characteristic (e.g., inductance, resistance) of a welding output circuit path connected to a welding power source is determined. A welding output waveform is selected from a plurality of welding output waveforms based on the determined electrical characteristics. As a result, the selected welding output waveform is matched to the welding output circuit path electrical characteristics to provide superior welding performance.

A method for cutting a wound hose (1), made from mutually engaging windings (11, 12, 13, 14) of a metallic tape (2), with the wound hose (1) being welded in a predetermined axial area (10) and then cut within the area (10) essentially in a plane (6) extending radially, with the wound hose (1) being axially compressed in the predetermined area prior to welding such that in the area (10) a mutual contacting of the windings (11, 12, 13, 14) occurs. The welding is performed along a predetermined number of windings (11-14) in the area (10), and the welding energy required for welding the windings is introduced via the area of the winding hose into it. Additionally, an accordingly produced wound hose (1) is provided and a device suitable for its production.

Systems and methods for providing an improved start in a welding are provided. The system may include a power circuit and a control circuit: The power circuit may generate welding output power for a welding process. The control circuit may control the start of the welding process, for example, by generating a current pulse.