Apparatus, systems, and/or methods for mitigating audible noise generated by a welding-type power supply are disclosed. In some examples, the switching frequency of the welding-type power supply may be changed to a frequency that is outside the audible range for humans. This strategy takes advantage of the fact that the observed audible noise is generated by vibrating components within the welding-type power supply that vibrate at a frequency related to the switching frequency. Other noise mitigation strategies include dithering and deactivation of portions of the welding-type power supply that vibrate to generate the audible noise.

A consumable electrode arc welding method includes: setting an optimal voltage and an increasing slope of a short circuit current to correspond to a setting current; feeding a consumable electrode wire; and alternately generating a short circuit condition and an arc condition, thereby carrying out welding, wherein the short circuit current is controlled by changing the increasing slope of the short circuit current according to a difference between the setting voltage and the optimal voltage when the setting voltage is different from the optimal voltage. With this, the increasing slope of the short circuit current and the current value corresponding to the inflection point of the short circuit current are automatically changed.

A welding wire feeder includes a wire feed drive and wire feed control circuitry coupled to the wire feed drive to control the drive of welding wire towards the welding application. The welding wire feeder includes power conversion circuitry configured to receive input power and to convert the input power to welding output suitable for a welding application, output voltage sensors configured to measure output voltage, output current sensors configured to measure output current, and control circuitry coupled to the power conversion circuitry and to the output voltage and current sensors. The power conversion circuitry includes power storage circuitry configured to store energy and to discharge at least a portion of the stored energy during an overdraw event. The control circuitry is configured to control the output current during the overdraw event to maintain a stored energy value of the power storage circuitry greater than a desired minimum energy value.

Hybrid welding modules are disclosed. An example hybrid welding module includes a welding input switch, an energy storage input switch, an energy storage output switching circuit, and a control circuit. The welding input switch receives welding-type input power and selectively outputs the welding-type input power to a weld circuit as first welding-type output power. The energy storage input switch receives the welding-type input power and selectively conducts the welding-type input power to an energy storage device. The energy storage output switching circuit converts energy output by the energy storage device to second welding-type power and outputs the second welding-type power to the weld circuit. The control circuit enables charging of the energy storage device by controlling the energy storage input switch to output the welding-type input power to the energy storage device, selectively controls the welding input switch to output the welding-type input power to the weld circuit, determines a commanded total welding-type current, monitors a first welding-type current through the welding input switch, monitors a second welding-type current output by the energy storage output switching circuit, and controls the energy storage output switching circuit to output the second welding-type power for combination with the first welding-type output power based on the commanded total welding-type current, the first welding-type current, and the second welding-type current.

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.

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 hybrid welding system is provided. In one embodiment, the welding system includes an engine-driven generator, an energy storage device, a contactor, and a controller. The controller may be configured to control delivery of weld power from the generator when a commanded output is below a threshold level, and from both the generator and the energy storage when the commanded output is above the threshold level. Closing of the contactor enables the energy storage device to contribute to weld power during welding operations and to be charged by the generator output independent of charging between weld operations. Additional hybrid welding systems and methods are also disclosed.

A welding wire feeder includes a wire feed drive and wire feed control circuitry coupled to the wire feed drive to control the drive of welding wire towards the welding application. The welding wire feeder includes power conversion circuitry configured to receive input power and to convert the input power to welding output suitable for a welding application, output voltage sensors configured to measure output voltage, output current sensors configured to measure output current, and control circuitry coupled to the power conversion circuitry and to the output voltage and current sensors. The power conversion circuitry includes power storage circuitry configured to store energy and to discharge at least a portion of the stored energy during an overdraw event. The control circuitry is configured to control the output current during the overdraw event to maintain a stored energy value of the power storage circuitry greater than a desired minimum energy value.

A power supply to provide welding power. The power supply may include a dc source providing a direct current (DC) voltage input; a bridge circuit comprising a first plurality of switches, the bridge circuit being disposed on a primary side of the power supply and being coupled to receive the DC voltage input, and to output a primary voltage signal; a transformer coupled to the bridge circuit to transform the primary voltage signal to a secondary voltage signal; a synchronous rectification circuit to receive the secondary voltage signal and generate a welding signal, the synchronous rectification circuit comprising a second plurality of switches; and a controller coupled to the bridge circuit and synchronous rectification circuit, to coordinate operation of the plurality of primary switches with operation of the plurality of secondary switches.

A welding-type system with a programmed controller and alert devices for alerting a user as to the impending thermal shutdown of the welding-type system.