A master unit includes a welding DB in which prescribed motion data associated with an object to be welded is stored, a state sensor which measures, as welding state data, a situation of welding by a robot which executes welding in a real environment according to the prescribed motion data, a simulated environment which imitates the real environment and notifies a worker of the welding state data, and a motion control unit which receives, as an input, worker motion data indicating a motion of welding by the worker from the simulated environment, operates the robot in the real environment by using the worker motion data instead of the prescribed motion data, and records, as new prescribed motion data, the input worker motion data in the welding DB.

An example welding user interface system includes: a user interface configured to receive a plurality of control inputs indicative of a plurality of weld specifications, wherein the plurality of weld specifications comprise two or more physical attributes of a weld, the physical attributes comprising two or more of a workpiece thickness, a joint type, a workpiece material, a fillet size, a penetration depth, a penetration profile, a bead width, a wire type, a wire feed speed, or a gas type; and a processor configured to convert the weld specifications from the plurality of control inputs into electrical parameters of a welding power source, and to control an output welding power of the welding power source based at least in part on the electrical parameters.

The present invention is directed to a system and method of remotely controlling a welding machine with command signals transmitted to the welding power source across a weld cable connecting the power source to a remote device, such a wire feeder. A transmitter transmits the control commands containing desired welding operational parameters to a receiver disposed in the power source across a weld cable also designed to carry welding power from the power source to the wire feeder.

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.

A robotic electric arc welding system includes a welding torch, a welding robot configured to manipulate the welding torch during a welding operation, a robot controller operatively connected to the welding robot to control weaving movements of the welding torch along a weld seam and at a weave frequency and weave period, and a welding power supply operatively connected to the welding torch to control a welding waveform, and operatively connected to the robot controller for communication therewith. The welding power supply is configured to sample a plurality of weld parameters during a sampling period of the welding operation and form an analysis packet, and process the analysis packet to generate a weld quality score, wherein the welding power supply obtains the weave frequency or the weave period and automatically adjusts the sampling period for forming the analysis packet based on the weave frequency or the weave period.

Systems are disclosed relating to a mobile device mounted to a welding helmet such that a wearer of the welding helmet can see a display of the mobile device when wearing the welding helmet. In some examples, the mobile device is mounted such that a camera of the mobile device is unobscured and positioned at approximately eye level, facing the same way the wearer's eyes are facing. In some examples, the simulated training environment may be presented to the user via the display screen of the mobile device, using images captured by the camera of the mobile device, when the mobile device is so mounted to the welding helmet.

In certain embodiments, a portable metal working robot system includes a metal working tool configured to perform a metal working process on one or more metal parts. In addition, the portable metal working robot system includes communication circuitry configured to receive control signals from a control system located remotely from the portable metal working robot system. The portable metal working robot system also includes control circuitry configured to control operational parameters of the portable metal working robot system in accordance with the received control signals.

Methods and apparatus to synergically control a welding-type output during a welding-type operation are disclosed. An example welding-type power supply includes a power conversion circuit configured to convert input power to welding-type power and to output the welding-type power to a welding-type torch; a communication circuit configured to receive a control signal from a remote control device during a welding-type operation; and a control circuit configured to synergically control a voltage of the welding-type power and a wire feed speed based on the control signal.

A portable advanced process module system includes, for example, a welding power source, an portable advanced process module, and a wire feeder. The portable advanced process module and the wire feeder are separately enclosed in suitcase style enclosures with disconnectable power and communication means between the portable advanced process module and the wire feeder. The processing unit includes power electronics to enable advanced weld processes that can be delivered to the wire feeder and a welding work piece. The portable advanced process module is powered by a DC bus that can be supplied by a welding power source. Connecting the portable advanced process module between the welding power source and the wire feeder enables advanced welding processes to be accomplished at great distances from the main welding power source. Separating the power electronics into the portable advanced process module and maintaining a standard suitcase wire feeder form factor keeps the welding equipment used in the working area envelope small, light, and portable.

Systems are disclosed relating to a mobile device mounted to a welding helmet such that a wearer of the welding helmet can see a display of the mobile device when wearing the welding helmet. In some examples, the mobile device is mounted such that a camera of the mobile device is unobscured and positioned at approximately eye level, facing the same way the wearer's eyes are facing. In some examples, the simulated training environment may be presented to the user via the display screen of the mobile device, using images captured by the camera of the mobile device, when the mobile device is so mounted to the welding helmet.