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 includes ramping down a welding current, generated by a power supply, that reaches a welding zone via a welding circuit, storing inductive energy from the welding circuit that is generated as a result of the ramping down to obtain stored energy, and selectively feeding the stored energy to the welding circuit.

Welding system and method permit exchange of data with Smart Grid monitors and/or controllers. The welding systems include a welding power supply configured to convert power between the power grid and the welding power supply. A grid interface cooperates with control circuitry to transmit data to and/or from the grid monitors and/or controllers on the grid side. The control circuitry may control operation of the welding power supply based upon data from the grid. The system may include power generation devices (e.g., engine-drive generators) and energy storage devices (e.g., batteries), The control circuitry may control operation of such devices, the exchange of power between them, and the draw of power from the grid or the application of power to the grid based upon the data exchanged with the grid monitors and/or controllers.

The present invention is directed to a welding-type power source that includes a power source housing and an engine arranged in the power source housing to supply electrical power. An energy storage device is included that is in rechargeable association with the internal combustion engine and arranged to provide welding-type power for at least a given period.

A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal, a network of switches switched at a high frequency with a given duty cycle to convert the input into a first internal AC signal, an isolation transformer with a primary winding driven by the first internal high frequency AC signal and a secondary winding for creating a second internal high frequency AC signal and a rectifier to convert the second internal AC signal into a second DC output signal of the second stage; with a magnitude related to the duty cycle of the switches and, a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module and the third stage is assembled into a second module connectable to the first module.

The present application relates to a welding system comprising a main module provided with an outer casing identifying an input port for the connection to a source of external electrical power, an electric generator configured to adapt the electrical characteristics of said electrical power to a first type of welding, at least an output port for the connection to a welding torch, an electronic control unit configured to control the functionality of said electric generator. Said main module comprises a mechanical and electrical connection unit of a first type, said welding system comprising at least an auxiliary module provided with an outer casing identifying an electric generator configured to adapt the electrical characteristics of an electrical power to a second type of welding, at least a mechanical and electrical connection unit of a second type couplable to said mechanical and electrical connection unit of a first type.

The present invention is directed to a welding-type power source that includes a power source housing and an engine arranged in the power source housing to supply electrical power. An energy storage device is included that is in rechargeable association with the internal combustion engine and arranged to provide welding-type power for at least a given period.

Disclosed herein are continuous welding systems and methods for changing electrodes in continuous welding operations. The continuous welding system may include a first and a second welding assembly. A controller may engage with each welding assembly and may individually energize either one of the welding assemblies or both welding assemblies to perform a continuous welding operation. Electrodes from one welding assembly may be removed and replaced without interrupting the operation of at least one other welding assembly. A method of changing electrodes in a continuous welding operation may include performing a welder swap sequence to replace one electrode from a first welding assembly without interrupting the operation of at least one other welding assembly.

Embodiments of the present invention are directed to a combustion engine power generation device, such as an engine driven welder, which utilizes a first battery for engine start and providing operational power when the system is off, and a second high storage battery to provide all operational power so long as the second battery has the stored energy to supply the needed power. In an embodiment, the first battery is a lead acid battery and the second battery is a lithium ion battery.