Methods and apparatus to communicate via a weld cable are disclosed. An example weld circuit communications device includes a receiver circuit, a processor, and a local communications adapter. The receiver circuit to receive a communication via a weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit, the communication including weld voltage feedback information measured at a device remote from a power supply and remote from the weld circuit communications device while the current is flowing through the weld circuit. The processor generates power supply control information based on the weld voltage feedback information. The local communications adapter transmits the power supply control information to control welding-type power output by a power converter to regulate a weld voltage to a weld voltage setpoint.

Apparatus and methods are provided for a welding-type power system that includes an engine comprising a starter battery. An electric generator is turned by the engine. A power bus connects an output of the generator to a welding-type output. A sensor measures a power demand on the power bus. A controller is configured to control the engine to adjust speed in response to a measured power demand on the power bus, and to control a converter to connect the starter battery to output power to the power bus in response to the measured power demand.

A method, performed in a welding or cutting system including a power supply configured to deliver a current to a welding torch to create an arc on a cut-off workpiece, comprises: sampling the current to produce digitized current values; filtering the digitized current values using a first digital filter to produce filtered digitized current values; sampling a voltage corresponding to the current to produce digitized voltage values; filtering the digitized voltage values using a second digital filter to produce filtered digitized voltage values; and controlling a current level of the current using the filtered digitized current values or the filtered digitized voltage values.

A real-time virtual reality welding system including a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of importing data into the virtual reality welding system and analyzing the data to characterize a student welder's progress and to provide training.

A welding system includes a welding power supply, wire feeder, and welding circuit connecting the power supply to the wire feeder. The power supply and the wire feeder are configured for bidirectional communication over the welding circuit. The power supply includes a voltage sensor that measures a voltage level, and a current sensor that measures a current level, on the welding circuit. The power supply is configured to operate in a first welding mode to output a power voltage level to the welding circuit to power the wire feeder in response to a communication from the wire feeder over the welding circuit. The power supply generates periodic voltage dip pulses on the welding circuit, and automatically switches to a second welding mode different from the first welding mode based on the voltage level on the welding circuit falling below a threshold voltage level during a voltage dip pulse.

A welding apparatus for welding workpieces by means of a welding arc which is ignited between a non-consumable welding electrode and the workpieces and produces a molten pool, wherein the welding is performed in a welding process including a plurality of welding cycles, the parameters of which can be set via an interface of the welding apparatus. Each welding cycle of the welding process has a high-current welding phase, during which a high welding current flows, and a low-current welding phase, during which a low welding current flows. In the high-current welding phase and/or in the low-current welding phase of, with the relevant welding cycle being set accordingly, current pulses can be applied, and at the beginning of the high-current welding phase, with the relevant welding cycle being set accordingly, high-frequency ignition pulses can be applied for the contactless ignition of the welding arc.

Apparatus and methods are provided for a welding-type power system that includes an engine configured to drive an electric generator to provide a first power output. An energy storage device to provide a second power output. A controller is configured to receive one or more control signals to provide a total power output to at least one of a welding-type output or an auxiliary type output, determine proportional values for the first power output and the second power output that add up to the total power output based on a power demand signal that indicates a contribution of the first power output and the second power output, control the engine to adjust speed based on the first power output value, and control a connection from the energy storage device to provide the second power output to the welding-type output based on the second power output value.

A display system for a welding helmet that includes a darkening filter layer, a high-dynamic range (HDR) camera system to capture an HDR light field, and an optical image stabilization subsystem. Captured images are displayed on an HDR electronic display within the welding helmet without risk of overexposure of ultraviolet radiation to the operator. In some examples, dual electronic displays are used to display different HDR images to each eye of the operator.

A method and a system for controlling a welding operation is provided by a welding machine controlled by an automatic motion generating mechanism. The method includes the steps of acquiring a set of welding data during the welding operation; computing at least a first part of the set of welding data and at least a second part of the set of welding data providing computed data, wherein the computed data indicate an abnormality; and transferring an abnormality output to a robot controller, which is controlling the welding machine and the automatic motion generating mechanism.

A method for generating a path for wire arc additive manufacturing is provided in this disclosure, which relates to the technical field of additive manufacturing, and includes following steps: generating a model in which a three-dimensional model is established according to angle constraint of the wire arc additive manufacturing; layering the model in which the three-dimensional model is layered along a height direction; selecting discrete points in which a plurality of discrete points are selected according to curve curvature for different layers of the model; obtaining coordinates of the discrete points; determining a printing direction; obtaining coordinates of the discrete points and corresponding printing directions; and generating a control program. The method according to the disclosure is simple, has a wide application range, can satisfy printing of complex shapes, and can serve to well form for structures with maximum printing inclination of 60 degrees, thus improving forming effect of printing.