A short circuit welding method with successive welding cycles with a respective arc phase and short circuit phase includes controlling at least the welding parameters welding current and feed speed of a melting electrode and feeding the electrode toward of a workpiece at a predetermined forward final speed at least during part of the arc phase and away from the workpiece at a predetermined rearward final speed at least during part of the short circuit phase. A device carries out this method. A change in the feed speed and a rearward final speed are predetermined and a welding current is controlled to complete the short circuit phase after reaching the rearward final speed and after 3 ms at the latest and repeat every 8 ms at the latest. The welding parameters are controlled such that the welding cycle duration8 ms, resulting in a welding frequency125 Hz.

A torch for connection to an electric arc welding system having a wire feeder, a power source and a weld process controller for the power source. The torch being connected to the front end of a welding gun, which gun has a rear end with a first unique component of a connector. The welding system has a second component of the connector matching the first component. The gun has a communication channel extending from the torch to the first component for transmitting data to the welding system through the connector. The torch has a memory with an identification code outputted on the communication channel to the first component and the system has a decoder circuit connected to the second component and responsive to a selected identification code.

A method and apparatus for controlling arc/short between a wire and a work piece is described. A current path parallel to the wire/work is provided. The voltage drop across the parallel path can be preset, to limit the wire/work voltage, or it can be controlled to a desired level. The control can be in response to feedback.

An example welding-type power supply includes: a transformer having a primary winding and first and second secondary windings; an input circuit configured to provide an input voltage to the primary winding of the transformer; first, second, third, and fourth switching elements, and a control circuit configured to: control the first, second, third, and fourth switching elements to selectively output a positive or negative output voltage without a separate rectifier stage by selectively controlling ones of the first, second, third, and fourth switching elements based on a commanded output voltage polarity and an input voltage polarity to the transformer; and prior to changing from a first output voltage polarity to a second output voltage polarity, controlling the first, second, third, and fourth switching elements to reverse the power flow to return reactive energy to an input circuit via the transformer.

Systems and methods for selecting a welding output waveform based on characterizing a welding circuit output path with respect to its electrical characteristics. At least one electrical characteristic (e.g., inductance, resistance) of a welding output circuit path connected to a welding power source is determined. A welding output waveform is selected from a plurality of welding output waveforms based on the determined electrical characteristics. As a result, the selected welding output waveform is matched to the welding output circuit path electrical characteristics to provide superior welding performance.

Systems and methods to reduce magnetic flux in a switched mode power supply are disclosed. An example welding-type power supply includes a switched mode power supply, including a transformer configured to transform an input voltage to a welding-type voltage; switches configured to control a voltage applied to the primary winding of the transformer; a current detector configured to measure a current through the primary winding; a flux accumulator configured to determine a net flux in the transformer based on a number of volt-seconds applied to the primary winding of the transformer; and a controller configured to: control duty cycles of the switches based on the net flux; and set a value of the net flux in response to the current through the primary winding satisfying a current threshold.

A torch for connection to an electric arc welding system having a wire feeder, a power source and a weld process controller for the power source. The torch being connected to the front end of a welding gun, which gun has a rear end with a first unique component of a connector. The welding system has a second component of the connector matching the first component. The gun has a communication channel extending from the torch to the first component for transmitting data to the welding system through the connector. The torch has a memory with an identification code outputted on the communication channel to the first component and the system has a decoder circuit connected to the second component and responsive to a selected identification code.

A method of operating a welding power supply during a welding process in which an electric arc between a consumable electrode and a work piece is generated while feeding the consumable electrode and moving the arc in relation to the work piece along a welding track, wherein a transition between a DC power output of the welding power supply and an AC power output of the welding power supply, or vice versa, is made without interruption of the welding process.

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.

A welding-type power supply includes a controller, a preregulator, a preregulator bus, and an output converter. The controller has a preregulator control output and an output converter control output. The preregulator receives a range of inputs voltages as a power input, and receives the preregulator control output as a control input, and provides a preregulator power output signal. The preregulator includes a plurality of stacked boost circuits. The preregulator bus receives the preregulator output signal. The output converter receives the preregulator bus as a power signal and receives the output converter control output as a control input. The output converter provides a welding type power output, and includes at least one stacked inverter circuit.