A welding system includes a welding power source configured to provide pulsed electropositive direct current (DCEP), a gas supply system configured to provide a shielding gas flow that is at least 90% argon (Ar), a welding wire feeder configured to provide tubular welding wire. The DCEP, the tubular welding wire, and the shielding gas flow are combined to form a weld deposit on a zinc-coated workpiece, wherein less than approximately 10 wt % of the tubular welding wire is converted to spatter while forming the weld deposit on the zinc-coated workpiece.

A robotic electric arc welding system includes a welding torch, a welding robot configured to manipulate the welding torch during a welding operation, a robot controller operatively connected to the welding robot to control weaving movements of the welding torch along a weld seam and at a weave frequency and weave period, and a welding power supply operatively connected to the welding torch to control a welding waveform, and operatively connected to the robot controller for communication therewith. The welding power supply is configured to sample a plurality of weld parameters during a sampling period of the welding operation and form an analysis packet, and process the analysis packet to generate a weld quality score, wherein the welding power supply obtains the weave frequency or the weave period and automatically adjusts the sampling period for forming the analysis packet based on the weave frequency or the weave period.

A method and apparatus for providing short arc welding-type power is disclosed. The system includes a power supply, a wire feeder, and a controller. The output current is decreased at dive rate when the arc forms. The dive rate is maintained until the currents drops to a threshold, preferably a function of the peak short current in that cycle. Then the current is held steady for a length of time that is a percentage of the short time for that cycle. Then the current is decreased at the normal rate until the short reforms, and the current begins increasing at the normal rate. The holding steady portion can be omitted.

A method and apparatus for providing short arc welding-type power is disclosed. The system includes a power supply, a wire feeder, and a controller. The output current is decreased at dive rate when the arc forms. The dive rate is maintained until the currents drops to a threshold, preferably a function of the peak short current in that cycle. Then the current is held steady for a length of time that is a percentage of the short time for that cycle. Then the current is decreased at the normal rate until the short reforms, and the current begins increasing at the normal rate. The holding steady portion can be omitted.

The present invention refers to a control method and welding equipment for MIG/MAG-welding with presence of short-circuiting droplets between an electrode end and a workpiece. The method comprises establishment of a short-circuiting time, establishment of an arc time, and controlling the energy supplied to the electrode. The energy supply is controlled in such a way that the energy supply is increased if a measured short-circuiting time of a total period time, where the period time is the sum of the short-circuiting time and the arc time, exceeds a defined adjustable set value and decreases if said short-circuiting percentage goes below said set value.

Embodiments of welding systems and methods with coordinated dual power outputs supporting a same welding process or a same AC output process are disclosed. One embodiment of a welding system includes an engine and a generator operatively connected to the engine, where the engine is configured to drive the generator to produce electrical input power. The welding system also includes a power supply operatively connected to the generator and having at least one controller. The power supply is configured to convert the electrical input power to form two power outputs that are coordinated with each other, at least in time, via the controller to support a same welding process. The same welding process may be, for example, a hotwire welding process, a tandem metal inert gas (MIG) welding process, or an alternating current (AC) output process.

A modular direct current power source is provided. One welding power supply system includes a plurality of hysteretic buck converters coupled in parallel. The hysteretic buck converters are configured to receive a common input and to provide combined output power to a common load based upon the common input.

A modular direct current power source is provided. One welding power supply system includes a plurality of hysteretic buck converters coupled in parallel. The hysteretic buck converters are configured to receive a common input and to provide combined output power to a common load based upon the common input.

Welding is performed by alternately switching a pulse arc welding period (where welding is performed by forward feeding a welding wire by a rotation for the forward feeding of a push side feeding motor and a rotation for the forward feeding of the pull side feeding motor and feeding a peak current and a base current) and a short-circuiting transition arc welding period (welding is performed by forward/backward feeding the welding wire by the rotation for the forward feeding of the push side feeding motor and a rotation for the forward/backward feeding of the pull side feeding motor and feeding a short-circuiting current and an arc current). During the short-circuiting transition arc welding period, a forward feeding peak value Wsp and/or a backward feeding peak value Wrp of a pull feeding speed Fw are compensation-controlled based on a wire storage amount of an intermediate wire storage.

Welding is performed by alternately switching a pulse arc welding period (where welding is performed by forward feeding a welding wire by a rotation for the forward feeding of a push side feeding motor and a rotation for the forward feeding of the pull side feeding motor and feeding a peak current and a base current) and a short-circuiting transition arc welding period (welding is performed by forward/backward feeding the welding wire by the rotation for the forward feeding of the push side feeding motor and a rotation for the forward/backward feeding of the pull side feeding motor and feeding a short-circuiting current and an arc current). During the short-circuiting transition arc welding period, a forward feeding peak value Wsp and/or a backward feeding peak value Wrp of a pull feeding speed Fw are compensation-controlled based on a wire storage amount of an intermediate wire storage.