In thin sheet welding, when a heat input amount relative to a sheet thickness is too large, a welding defect such as a deviation from aim due to occurrence of a strain or burn through may easily occur. When a welding current is decreased to reduce the heat input amount, there is an issue in which an arc tends to become unstable. In arc welding in which short-circuit and arcing are repeated, first heat input period (Th) and second heat input period (Tc) having a heat input amount less than that of first heat input period (Th) are periodically repeated and a welding current during an arc period in second heat input period (Tc) is decreased to extinguish the arc. This reduces the heat input amount into a welding object and suppresses burn through or a strain upon welding, while making the arc stable.

The invention described herein generally pertains to a welder system that includes one or more welding power sources, an input device having a display and an imaging device, and a fabrication computer device. The fabrication computing device includes a processor configured to execute computer-executable instructions that configure the fabrication computing device to receive an informational input from the input device. The informational input is based at least in part on an image captured by the imaging device of the input device, and the informational input is indicative of one or more of a weld procedure, an operator identifier, a welding power source identifier, a part identifier, or an operation status. The fabrication computing device is further configured to control operation of at least one welding power source of the one or more welding power sources based on the informational input received.

In thin sheet welding, when a heat input amount relative to a sheet thickness is too large, a welding defect such as a deviation from aim due to occurrence of a strain or burn through may easily occur. When a welding current is decreased to reduce the heat input amount, there is an issue in which an arc tends to become unstable. In arc welding that repeats short-circuit and arcing, first heat input period (Th) and second heat input period (Tc) having a heat input amount less than that of first heat input period (Th) are periodically repeated. This reduces the heat input amount into a welding object and suppresses burn through and a strain upon welding while making the arc stable.

Disclosed are welding systems and methods for conducting a completed circuit testing process. The welding system includes a power source to deliver power via one or more power outlets. Control circuitry receives an input to initiate a welding process and to command the power source to deliver a power signal with a current below a threshold level. The control circuitry monitors characteristics of the power signal at the one or more power outlets and determines whether a completed circuit condition exists. The control circuitry performs this determination based on information obtained through monitoring the characteristics of the power signal. The control circuitry controls the power source to prevent delivery of power if a completed circuit condition exists.

A method and apparatus for providing welding type power includes receiving input power and pulse width modulating a first forward converter and a second forward converter so that they operate as a pulse width modulated double forward converter to provide a welding type output. A phase relationship between the first forward converter and a second forward converter is selected from at least two available phase relationships using a controller. The controller includes a pwm module, and the pwm module includes a phase relationship module. The at least two available phase relationships are at least two of variable phase shifting, fixed phase staggering and locked in phase. The selected phase relationship is maintained over a predetermined range of outputs.

In some aspects, contact members to connect plasma torch leads to plasma cutting systems can include: a base portion; a set of ports within the base portion that include: a coolant supply port to convey a liquid coolant from the cutting system to a plasma arc torch connected to the contact member by the torch lead, a coolant return port: i) to convey return liquid coolant from the torch to the cutting system, and ii) to convey an operational current from the cutting system to the torch, at least one gas supply port to convey processing gases to the torch, and an ohmic contact connector; and a connector to couple the base portion to the cutting system and connect each of the ports and electrical connectors to respective complementary connections of the cutting system upon coupling to the cutting system.

Methods and systems for creating and controlling an AC output for welding, plasma cutting or heating are provided. One embodiment of the present disclosure achieves a desired square wave AC output and reduces the number of circuit components needed by combining components of a buck converter and a full bridge inverter. Current flow paths through a power control circuit that are generated via switching of transistors in the circuit on and off are provided. In one embodiment, a pulse width modulation leg, which controls the level of current flow through an inductor, is provided. Certain embodiments include a bidirectional buck converter that converts an unregulated DC flow to a regulated DC flow through an inductor. In one embodiment, a steering leg is provided, which controls a direction of current flow through the inductor. Additionally, an output clamp circuit, which suppresses the parasitic load inductance during polarity reversal is provided.

Embodiments of a high speed laser hot wire spraying system are disclosed. In one embodiment, a laser subsystem includes a laser power oscillator and a laser focusing device to generate a laser beam directed toward a substrate. The laser focusing device includes a high velocity coaxial gas nozzle to direct, coaxially with the laser beam, a stream of inert gas toward the substrate. A hot wire subsystem includes a power supply and a wire feeding device to feed a consumable metal wire toward the laser beam while resistively pre-heating a distal portion of the consumable metal wire. The laser beam provides energy to liquefy the distal portion of the consumable metal wire upon intersecting the laser beam. The stream of inert gas has a velocity to cause the distal portion of the consumable metal wire to be sprayed as liquefied particles onto a surface of the substrate.

A welding machine includes a welding power supply, a chassis structure that forms an engine compartment, and an internal combustion engine located within the engine compartment. A generator is connected to the power supply to supply electrical energy thereto. The generator comprises a rotor shaft driven by the engine. The machine includes an air compressor, or hydraulic pump, having a driven pulley. An axial generator cooling fan is driven by the rotor shaft. The fan has fan blades extending between a central hub attached to the rotor shaft and an annular pulley ring connecting the fan blades. The pulley ring is coupled to the driven pulley to power the air compressor or the hydraulic pump. A fuel tank is mounted within the chassis structure beneath the engine and generator. The fan generates a first cooling air flow cooling the generator, and a second cooling air flow cooling the fuel tank.

A welding system includes a multi-process power supply, a TIG torch, and a TIG power pin for connecting the TIG torch to the multi-process power supply. The multi-process power supply has a power output connection for a MIG torch and a controller. The Controller is configured to command shielding gas and welding current to be provided to the power output connection, and the power output connection is configured to provide the shielding gas and the welding current to a MIG torch when the MIG torch is connected to the power output connection. The TIG power pin connects the TIG torch to the power output connection such that the power output connection is configured to provide the shielding gas and the welding current to the TIG torch. The controller is configured such that at least one of the shielding gas and the welding current is not provided to the TIG torch through the power output connection until a user engages a control member.