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 including a first power supply device and a second power supply device that are connected in common to a load. The first power supply device calculates control information for controlling voltage or current to be output to the load and source information for obtaining the control information, and controls the output to the load based on the calculated control information while transmitting the source information to the second power supply device. The second power supply device receives the source information transmitted from the first power supply device, calculates control information based on the received source information, and controls the output to the load while detecting current to be output from itself to the load and transmitting current information to the first power supply device. The first power supply device receives the current information and calculates control information and source information based on the received current information and the current and voltage detected by itself.

Automatically identifying interchangeable torch components, such as consumables, for welding and cutting torches includes adding one or more passive markings to a surface of an interchangeable torch component. Then, automatic identification can be effectuated by a torch assembly including a torch body and one or more imaging devices or a system including the torch assembly and a power supply. The torch body has an operative end configured to removably receive one or more interchangeable torch components including one or more passive markings. The one or more imaging devices are positioned to optically acquire an image of or image data representative of the one or more passive markings included on the one or more interchangeable torch components so that the one or more interchangeable torch components can be automatically identified based on the one or more passive markings. Consequently, various components can be reliably and consistently identified.

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.

An example welding apparatus includes a welding power source configured to output current between a consumable electrode and a workpiece; a feeding apparatus configured to move the consumable electrode toward the workpiece; and circuitry. The circuitry is configured to: control the welding power source to repeat a sequence including: outputting a positive peak current from the workpiece to the consumable electrode during a positive peak period; outputting a first base current between the consumable electrode and the workpiece during a first base period following the positive peak period, an absolute value of the first base current being less than the positive peak current; and outputting a negative peak current from the consumable electrode to the workpiece during a negative peak period following the first base period, an absolute value of the negative peak current being greater than the absolute value of the first base current. The circuitry is further configured to control the feeding apparatus to move the consumable electrode close to the workpiece so as to temporarily short circuit the consumable electrode and the workpiece during the first base period.

A welding system includes a welder configured to output welding power to generate an arc between a welding electrode and a workpiece. The welding system also includes a power pin configured to be coupled to the welder in a first orientation or a second orientation. The power pin is configured to switch the welding power from a first polarity to a second polarity when the power pin is switched from being coupled to the welder in the first orientation to being coupled to the welder in the second orientation.

In one embodiment, a welding system includes an engine and a generator connected to the engine. The welding system also includes a power source having a controller. The power source is electrically connected to a welding electrode and a workpiece. The controller determines that an electrical load on the welding system has not been detected for a first time period while the engine is running, determines that a coolant temperature meets a minimum requirement, commands shutdown of the engine when the load has not been detected for the first time period and when the coolant temperature meets the minimum requirement, determines that the load has been detected (due to a single contact of the welding electrode to the workpiece) during a second time period after the engine has been shut down, and commands restart of the engine when the load has been detected during the second time period.

A low voltage system and method for servicing welding equipment including a service tool that may provide a low voltage power source to the welding equipment, enabling the welding equipment to be tested in a low voltage mode of operation. The service tool may also run various test sequences on the welding equipment operating in a low voltage mode of operation to troubleshoot and diagnose any issues with the circuitry of the welding equipment.

The invention provides a double-power-supply switching control system for a welding machine and method. The welding machine double-power-supply switching control method comprises the steps of: continuously detecting and modifying an input voltage signal by a signal modification unit; under the control of a control unit, judging, by a judgment unit, whether to perform voltage doubling, controlling to execute voltage doubling switching action, and locking an actual input voltage mode of a welding machine by a locking unit; and finally outputting matched output current by a power supply output unit.

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.