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 power supply system includes multiple power supply devices connected in common to a load. A first power supply device calculates control information for controlling voltage or current to be output to the load and controls the output to the load based on the calculated control information while transmitting the control information to a second power supply device. The second power supply device receives the control information transmitted from the first power supply device and control the output to the load based on the received control information while detecting current to be output from its own device to the load and transmitting current information to the first power supply device. The first power supply device receives the current information transmitted from the second power supply device and calculate control information based on the received current information and the current and voltage detected by its own device.

Welding brush systems having split heads designed to improve welder performance at least on Lincoln SA200, SA250, SA300, SAE300, SA200D, SA300D and Classic 1, 2 and 3 models of portable powered DC welders with commutators.

An apparatus is disclosed. The apparatus has a power supply, a control device connected to the power supply, a welding device selectively connected to the power supply via the control device, and a switch connected between the control device and the welding device. The control device includes a time delay relay that measures a predetermined time period. The switch maintains a closed position when the predetermined time period expires and the welding device is producing a welding arc. The switch switches from the closed position to an open position when the predetermined time period expires and the welding device stops producing the welding arc. The control device transfers current from the power supply to the welding device when the switch is in the closed position, and blocks current from the power supply to the welding device when the switch is in the open position.

A contact tip assembly with a preheating tip comprises a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding-type electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.

A pulsed welding regime includes a peak phase in which energy is added to an electrode and a weld puddle, and a molten ball begins to detach from the electrode, followed by a dabbing phase in which current is significantly reduced to place the ball in the weld puddle with addition of little or no energy. The resulting short circuit clears and the system proceeds to a background phase. The current in the dabbing phase is lower than the current during the background phase. The process may be specifically adapted for particular welding wires, and may be particularly well suited for use with cored wires. The dabbing phase allows for lower energy to be transferred to the sheath of such wires, and resets the arc length after each pulse cycle.

A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter and a controller. The controller includes a pwm module that sets the pwm timing signals. The pwm module includes a phase shift module that has a leading edge adjusted output and a trailing edge adjusted output responsive to the output load. The phase shift module also includes a duty cycle offset module and/or a Dmax module that is responsive to the output load current. The pwm module includes a disabling module responsive to at least one of the output current and output voltage that disables one of the first and second converters.

A method and apparatus for providing welding type power includes a phase shifted double forward converter having a first and second converter with a controller and an output rectifier. The output rectifier has at least one cathode current path that creates a cathode magnetic field when current flows in the cathode current path. The output rectifier also has at least one anode current path that creates an anode magnetic field when current flows in the anode current path. The cathode current path is disposed and oriented and the anode current path is disposed and oriented such that the cathode magnetic field acts to at least partially cancel the anode magnetic field.

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.

An apparatus comprises: a power supply to generate a pulsed current waveform defined by current waveform parameters for an arc welding process; and a control module configured to present, and to receive selections of, selectable settings that vary over a dynamic range to control values of the current waveform parameters, wherein the selectable settings include a nominal setting that corresponds to nominal values of the current waveform parameters, and wherein the control module is configured to, upon receiving a selection of each selectable setting that differs from the nominal setting, cause the power supply to automatically adjust the values in combination relative to the nominal values according to a variation scheme as a function of each selectable setting over the dynamic range.