A simulator facilitates virtual welding activity of boss (e.g., orbital) weld joints. The simulator may include a logic processor based system operable to execute coded instructions for generating an interactive welding environment that emulates welding activity on a section of virtual pipe having at least one virtual weld joint. It also includes a display connected to the logic processor based system for visually depicting the interactive welding environment, wherein the display depicts the section of virtual pipe. A pendant is provided for performing welding equipment setup and virtual welding activity on the at least one weld joint in real time where one or more sensors are adapted to track movement of the input device in real time for communicating data about the movement of the input device to the logic processor based system.

The invention relates to a method and a device (1) for welding by means of a non-consumable electrode (2), wherein a welding current (I) alternating in polarity at a welding frequency (f.sub.S) is applied by a current source (3) between the electrode (2) and a workpiece (4) in order to form an arc (5), and the polarity is changed back to the polarity before the polarity change if the voltage (U) is above the voltage threshold value (U.sub.S+, U.sub.S−) and the welding current (I) is below the current threshold value (I.sub.S+, I.sub.S−). According to the invention, the welding voltage (U) and the welding current (I) after a preset duration (Δt) after the polarity change are compared with the voltage threshold value (U.sub.S+, U.sub.S−) and the current threshold value (I.sub.S+, I.sub.S−), and in addition the power (P) in the arc (5) is determined, and the polarity is changed back if the welding voltage (U) is greater than the voltage threshold value (U.sub.S+, U.sub.S−), and/or if the welding current (I) is less than the current threshold value (I.sub.S+, I.sub.S−), and/or the determined power (P) is less than a preset power threshold value (P.sub.S).

An engine-driven welder/generator is controlled by an integrated controller that is coupled to both the engine and to the welder/generator. The controller receives input signals for operational parameters of the engine, and additional signals indicative of electrical output by the welder/generator. Operation of the engine and welder/generator may thus be coordinated. The controller may control speed, timing, fuel injection, and so forth of the engine, and output of the welder/generator, such as by control of input to a field coil.

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.

A method of identifying and selecting welding electrodes and welding output parameters on a welding power source is provided. The method includes identifying electrodes and/or electrode packaging with distinct colors and/or patterns which correspond to properties of the electrode. The method also may include employing distinguishable identifying markings on a power supply which correspond to the electrodes to be used to allow for easy setting of output parameters.

A welding system includes power supply configured to provide a welding power output. The welding system also includes a welding helmet having an electronic display and an inertial measurement unit. The electronic display is configured to display a representation of the power supply and to display one or more indications of one or more parameters of the power supply. The inertial measurement unit is configured to detect movement of the welding helmet. The welding system also includes a processing system communicatively coupled to the inertial measurement unit and configured to adjust at least one parameter of the one or more parameters based at least in part on the movement of welding helmet.

An arc welding system includes a welding power supply having a switching type power converter. A welding electrode is connected to the switching type power converter to receive electrical energy therefrom and produce an electric arc. A variable-frequency auxiliary power supply supplies electrical energy to an auxiliary load through an auxiliary power output of the arc welding system. An engine-generator is connected to the welding power supply and the variable-frequency auxiliary power supply, to supply electrical energy to the welding power supply to produce the arc, and to supply further electrical energy to the variable-frequency auxiliary power supply. A controller is operatively connected to the variable-frequency auxiliary power supply and is configured to control an output voltage frequency of the variable-frequency auxiliary power supply according to an auxiliary power supply frequency setting. The output voltage frequency of the variable-frequency auxiliary power supply is independent from engine speed of the engine-generator.

A welding system includes at least one high intensity energy source to create a weld puddle during a root pass on a narrow joint of a workpiece with a clad layer. The system also includes a controller to control a weld ramp out process such that, as the molten puddle advances to a start of an existing root pass weld, the controller at least one of decreases an energy output of the at least one high intensity energy source and reduces an interaction time between the at least one high intensity energy source and the weld puddle. After completion of the root pass, a thickness of a root pass weld in a region that is at or near the start point of the existing root pass weld is in a range of 100 percent to 130 percent of a nominal root pass thickness of a remainder of the root pass weld.

Methods and apparatus to communicate via a weld cable are disclosed. An example welding accessory includes a first port to receive input power via a first weld cable, a power converter to convert the input power to output power, a second port to output the input power via a second weld cable, and one or more output switches to selectively divert the input power from the power converter to the second port.

A welding system includes power supply configured to provide a welding power output. The welding system also includes a welding helmet having an electronic display and an inertial measurement unit. The electronic display is configured to display a representation of the power supply and to display one or more indications of one or more parameters of the power supply. The inertial measurement unit is configured to detect movement of the welding helmet. The welding system also includes a processing system communicatively coupled to the inertial measurement unit and configured to adjust at least one parameter of the one or more parameters based at least in part on the movement of welding helmet.