Dynamic range enhancement methods and systems for display for use welding applications are described. A display system in a dynamic range enhancement system can include, for example, a splitter, a high density filter, a low density filter, a first image sensor, a second image sensor, a graphical circuit, and a display. The high density filter and the first image sensor can be disposed in a first path. The low density filter and the second image sensor can be disposed in a second path. The first image sensor can receive filtered electromagnetic waves from the high density filter. The second image sensor can receive filtered electromagnetic waves from the low density filter. The graphic circuit can combine the signals from the first image sensor and the second image sensor to provide a high dynamic range image or video that is displayed on the display of a welding helmet, for example.

A tool welding system is disclosed that includes a table that heats a tool. A multi-axis robot includes a welding head that is moved relative to the table in response to a command. A controller is in communication with the robot and generates the command in response to welding parameters. The weld parameters are based upon a difference between an initial tool shape and a desired tool shape. The difference between the initial tool shape and the desired tool shape corresponds to a desired weld shape. The desired weld shape is adjusted based upon initial tool shape variations, which includes thermal growth of the tool. The tool is welded to provide the desired weld shape to achieve a desired tool shape.

A welding system includes a welding station having a weld station computer and a weld system in communication with the weld station computer. The weld system includes a supply of weld material, a welding device, and a weld supply motor assembly that moves the weld material to the welder device. The system further includes a weighting device operatively connected with the weld station computer to measure a weight of the supply of weld material and to communicate the weight of the supply of weld material to the weld station computer; and a sensor operatively connected with the weld supply motor assembly and the weld station computer so as to communicate the speed of the weld supply motor assembly to the weld station computer. The weld station computer is operatively connected to the weld supply motor assembly to control the speed of the motor assembly based on the weight data.

A self-contained speed indicator (10) that can be placed next to a weldment (11) and configured for a desired speed, which then provides a target speed indicator (10) to help a welder (14) practice maintaining that desired speed.

A system (10) and method for determining welding speed employing a series of optical sensors (28) positioned along a weld joint (12) that collects light source location data during an actual weld.

A new welding system is provided that makes use of breath of the operator to control one or more operating parameters of the power source or welding machine (or “welder”). The welding system may be configured for arc welding, and the welding machine or welder may include a constant voltage power source with varying current (or vice versa). In such an embodiment, the welding system includes a breath-based controller with a mouthpiece through which the operator can breathe or blow in air. The breath-based controller processes the user's breath to determine user input, and this operator input is communicated to the welder or welding machine (via wired or wireless communication links) to control arc intensity (i.e., current for a constant voltage welding machine) or arc length (i.e., voltage for a constant current welding machine). An operator uses the breath-based controller to remotely control the welding machine with high precision.

An example engine-driven welding-type power supply includes: an engine; a generator configured to convert mechanical power from the engine to electrical power; power conversion circuitry to convert the electrical power to welding power and to output the welding power via output terminals; and control circuitry configured to, while the engine is stopped, automatically start the engine in response to detecting a welding circuit scratch via the output terminals.

There is described a modular welding device having a welding torch assembly defining a welding axis and having a welding torch rotatable about the welding axis. The welding device further includes a drive assembly releasably attachable to the welding torch assembly and operable to linearly translate the welding torch assembly along an axis of translation. When the drive assembly is attached to the welding torch assembly in a first orientation relative to the welding torch assembly, the drive assembly is detachable from the welding torch assembly and re-attachable to the welding torch assembly so as to be disposed in a second orientation relative to the welding torch assembly.

A method includes displaying, on a display of a welding torch, a welding parameter in relation to a predetermined threshold range for the welding parameter, a target value for the welding parameter, or some combination thereof as a position of the welding torch changes, an orientation of the welding torch changes, a movement of the welding torch changes, or some combination thereof, to enable a welding operator to perform a welding operation with the welding parameter within the predetermined threshold range, at the target value, or some combination thereof. The welding parameter is associated with the position of the welding torch, the orientation of the welding torch, the movement of the welding torch, or some combination thereof.

A contact tip assembly having an electric contact unit containing a contact tip with an electric energy source, where the electric contact unit is positioned at a distance away from the outlet opening of a guide.