A welding system includes a power supply configured to generate a welding waveform. A wire feeder conducts the welding waveform to a wire electrode, and includes a drive motor that drives the wire electrode bidirectionally, a motor current sensor that senses a current level of the motor, and a controller that receives a current level signal from the motor current sensor and controls operations of the motor. A welding current sensor senses welding current level, and a welding voltage sensor senses welding voltage level, and the sensors are located with the power supply or the wire feeder. The controller is configured to determine a contact event between the wire electrode and a non-workpiece object based on the current level signal from the motor current sensor and one or both of the welding current level and the welding voltage level, and automatically retract the wire electrode upon determining the contact event.

A device for imparting a torsional force onto a wire has a base and a support mounted so as to be rotatable with respect to the base around an axis of rotation. The axis of rotation coincides with a wire path extending through the base and the support. Further, a wire clutching device is mounted on the support and adapted to engage at a wire guided along the wire path, and a rotation mechanism is provided which is adapted for rotating the support with respect to the base.

A device for imparting a torsional force onto a wire has a base and a support mounted so as to be rotatable with respect to the base around an axis of rotation. The axis of rotation coincides with a wire path extending through the base and the support. Further, a wire clutching device is mounted on the support and adapted to engage at a wire guided along the wire path, and a rotation mechanism is provided which is adapted for rotating the support with respect to the base.

Systems and methods are described to address issues associated with welding with cored wires. In certain processes, a welding wire may “stick” or fuse to a contact tip, such as at termination of a weld. To mitigate the negative effects of a wire fusing to a contact tip, the wire remains in motion at a time prior to the end of the weld, as the weld ends, and/or for a time after the end of the weld, to limit and/or eliminate fusion between the wire and the contact tip.

A method of controlling arc welding with a consumable electrode includes repeating the following periods in sequence: a short-circuit welding period to perform short-circuit arc welding; a pulse welding period to perform pulse welding; and a cooling period in which the welding current output is zero.

A method of controlling arc welding with a consumable electrode includes repeating the following periods in sequence: a short-circuit welding period to perform short-circuit arc welding; a pulse welding period to perform pulse welding; and a cooling period in which the welding current output is zero.

A robotic welding device employing a flexible guide rail comprises: a control box (2) pre-storing various welding processes and generating a welding parameter; a wire feed mechanism (7) feeding a welding wire to a welding gun (4); a flexible guide rail (8) attached to a welding component with the flexibility thereof; a welding robot comprising a robot body (3) and a welding gun (4), the robot body (3) being movably disposed on the flexible guide rail (8) along the same, and the welding gun (4) being disposed on the robot body (3) and controlled by the same to weld the welding component; a demonstrator (6) signally connected with the welding robot and the control box (2), controlling, a traveling path and an operation position of the welding robot, and adjusting oscillation and welding operations of the welding gun (4) according to an instruction of the control box (2); a remote control terminal (11) signally connected with the control box (2) so as to remotely monitor and configure the welding parameter, and signally connected with a data acquisition device of the welding robot so as to remotely monitor and configure the welding parameter during a welding process; and a welding power supply (1). The device enables automatic welding of a component with straight shape or arc shape.

A robotic welding device employing a flexible guide rail comprises: a control box (2) pre-storing various welding processes and generating a welding parameter; a wire feed mechanism (7) feeding a welding wire to a welding gun (4); a flexible guide rail (8) attached to a welding component with the flexibility thereof; a welding robot comprising a robot body (3) and a welding gun (4), the robot body (3) being movably disposed on the flexible guide rail (8) along the same, and the welding gun (4) being disposed on the robot body (3) and controlled by the same to weld the welding component; a demonstrator (6) signally connected with the welding robot and the control box (2), controlling, a traveling path and an operation position of the welding robot, and adjusting oscillation and welding operations of the welding gun (4) according to an instruction of the control box (2); a remote control terminal (11) signally connected with the control box (2) so as to remotely monitor and configure the welding parameter, and signally connected with a data acquisition device of the welding robot so as to remotely monitor and configure the welding parameter during a welding process; and a welding power supply (1). The device enables automatic welding of a component with straight shape or arc shape.

Disclosed is an arc welding control method of controlling a welding current in short-circuit arc welding of feeding a welding wire toward a base metal and alternating a short-circuit state and an arc state. The arc welding control method includes: executing, in the short-circuit state, a first increase in the welding current with a first slope, a first decrease in the welding current to a first bottom value after executing the first increase, a second increase in the welding current with a second slope after executing the first decrease, and a second decrease in the welding current to a second bottom value that is smaller than the first bottom value after executing the second increase to shift a state to the arc state.

Disclosed is an arc welding control method of controlling a welding current in short-circuit arc welding of feeding a welding wire toward a base metal and alternating a short-circuit state and an arc state. The arc welding control method includes: executing, in the short-circuit state, a first increase in the welding current with a first slope, a first decrease in the welding current to a first bottom value after executing the first increase, a second increase in the welding current with a second slope after executing the first decrease, and a second decrease in the welding current to a second bottom value that is smaller than the first bottom value after executing the second increase to shift a state to the arc state.