A multi-process welding machine provides an intuitive user interface to enable a user to select among different welding processes, and to select parameters for a given selected welding process. The multi-process welding machine also provides an arrangement by which a switching module, or DC to AC converter, of an AC TIG unit can be controlled to alternatively supply AC or DC welding voltages or current. Further, a configuration of switches can be leveraged to automatically (or manually) control the polarity of welding cables for different processes and to engage or disengage a wire feeder when, e.g., a MIG welding process is selected, or not selected, respectively. Finally, in an embodiment, the ferrite or magnetic materials used for a main output inductor and an high frequency starting inductor of the welding machine can be combined.

An example welding power supply includes: power conversion circuitry configured to convert supply power to welding current and to output the welding current to at least one of a shielded metal arc welding (SMAW) electrode or a gouging torch; a voltage sense circuit configured to measure an output voltage of the power conversion circuitry; and control circuitry configured to: control the power conversion circuitry using a current-controlled control loop based on a target current; while the output voltage is above a lower voltage limit, control the target current based on a difference between a reference voltage and the output voltage; and in response to detecting that the output voltage has decreased below the lower voltage limit, control a welding current output by the power conversion circuitry based on a first exponential relationship.

A welding regime may implements cyclic short circuits under a closed loop voltage control approach. Upon clearing or imminent clearing of the short circuit, a current recess is implemented. The current recess reduces the current that would otherwise be applied to the weld, resulting in multiple benefits. The recess may be implemented by suspending voltage command signals. Following the current recess, normal control is resumed with the then-current voltage command.

A system and method for operating an welding-based power source includes an welding-type power source includes a power conditioner configured to receive power from a power source and condition the power to have characteristics within a predefined set of thresholds and an inverter configured to receive the conditioned power from the power conditioner and convert the conditioned power to AC power. The welding-type power source also includes a rectifier configured to convert the AC power to DC welding-type power to drive a welding-type process and a processor segregated into at least two functional modules. The processor may be a field programmable gate array (FPGA) based processor. A first functional module is configured to control the power conditioner to condition the power to have characteristics within the predefined set of thresholds and a second functional module is configured to control the inverter to convert the conditioned power to AC power.

A welding-type power system that includes an engine and an electric generator driven by the engine. A power bus configured to connect a power output of the electric generator to one or more of a welding-type output, a power storage device, and a switched mode power supply. A plurality of sensors are configured to monitor a plurality of parameters associated with power demand to and from the power bus and generate a signal indicative of the power demand to and from the power bus based on the monitored plurality of parameters. A controller is configured to receive the signal from the plurality of sensors, the controller to control the engine speed in response to the signal or the power demand.

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 controller has a converter control output connected to the control input, and a flux balancing module. The converter control output is responsive to the flux balancing module such that the flux in the transformer remains balanced.

Welding-type systems and user interfaces having a color display for displaying physical setup instructions are disclosed. Example interface devices include a process selection input device, a display device, a memory, and a processor. The memory stores weld connection setup graphics and physical welding connections. Each of the plurality of weld connection setup graphics is a graphic of a perspective view of a power supply. The processor, in response to identifying a selected welding process type via the welding process selection input device, displays one of the plurality of the weld connection setup graphics via the display device. The processor detects a physical welding connection made at the power supply, determines, based on the detected physical welding connection, that the detected physical welding connection is incorrect for the selected welding process type, and displays an alert on the display device to indicate an error in the detected physical welding connection.

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.

A method includes displaying, on a display of a welding torch, a welding parameter in relation to a predetermined threshold range for the welding parameter, a target value for the welding parameter, or some combination thereof as a position of the welding torch changes, an orientation of the welding torch changes, a movement of the welding torch changes, or some combination thereof, to enable a welding operator to perform a welding operation with the welding parameter within the predetermined threshold range, at the target value, or some combination thereof. The welding parameter is associated with the position of the welding torch, the orientation of the welding torch, the movement of the welding torch, or some combination thereof.

Embodiments described herein include wireless control of a welding power supply via portable electronic devices, such as dedicated original equipment manufacturer (OEM) welding remote devices, cellular radio telephones, satellite radio telephones, laptops computers, tablet computers, and so forth. In particular, operating parameters and statuses of the welding power supply may be modified by the portable electronic device, as well as be displayed on the portable electronic device. A pairing procedure may be used to pair the welding power supply and the portable electronic device in a wireless communication network. Furthermore, in certain embodiments, a method of providing location services for the welding power supply includes utilizing location data for the portable electronic device controlling the welding power supply as an approximation for the location of the welding power supply.