Abstract:
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.
Abstract:
A system (100, 200, 300, 500, 600, 700, 900) and method of welding is provided where welding power supply (101) has a first output electrically coupled to a welding electrode (105) and a second output electrically coupled to a switching mechanism (201, 301, 503, 601, 701, 907; 3A, 5B, 5C, 5D). The welding power supply (101 ) provides a welding current through either of the first and second outputs to weld at least one work piece (W, W'). The switching mechanism (201, 301, 503, 601, 701, 907; 3A, 5B, 5C, 5D) has at least a first and second switch position, where the first switch position is coupled to a first position on the at least one work piece (W, W) and the second switch position is coupled to a second position on the at least one work piece (W, W), which is remote from the first position. During welding the switching mechanism (201, 301, 503, 601, 701, 907; 3A, 5B, 5C, 5D) switches between the first and second switch positions to change a current path (C1, C2, CP) for the welding current during through the at least one work piece (W, W').
Abstract:
An electric arc welder (100) and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode (E) and a workpiece (W). The welder (100) includes a short - detecting capability for detecting a short condition upon occurrence of short circuit between the advancing electrode and the workpiece. The welder (100) may also include a switching module (110) in the welding circuit path o: the welder (100) having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module (110), or by controlling a portion of a waveform of the welding process during the blanking interval.
Abstract:
A semi-automatic welding work cell, including a welding job sequencer that automatically selects a welding schedule for use by an operator in the semi-automatic welding work cell. The automatic selection may be by way of elapsed time, a detection of welding operations, a detection of the amount of welding wire supplied for the welding operation, or a detection of the amount of energy supplied for the welding operation.
Abstract:
A system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current weld layer.
Abstract:
Systems (100, 600, 700) and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources (610, 620) of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool (6). Furthermore, a wire feed speed of a welding electrode (E) may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance.
Abstract:
A system and method is provided to use a laser system to remove excess weld bead (10; 10a) build up from a workpiece (12; 14) after a welding operation. After a weld bead is formed a weld bead can have a protrusion which extends above a surface of a workpiece and it is desirable to remove the protrusion. A system and method is provided which uses a laser beam (125) oriented at an angle and delivered with an intensity sufficient eliminate or remove the excess weld bead (10a) build up.
Abstract:
Systems (100) for and methods of determining that a consumable welding package (110) has been, or may have been, replenished in a high production welding environment and that a tracked weight value of the consumable weld- ing package should be reset. An operator of a welding system (100) can be notified that a consumable welding package (110) may have been replenished and, therefore, that the weight value of the consumable welding package (110) may need to be reset in the welding system (100). Alternatively, the weight value of the consumable welding package (110) in the welding system (100) may be automatically reset when the welding system (100) has determined that the consumable welding package has been replenished.
Abstract:
A system (100) for and a method of starting a welding operation is provided where an electrode (107) is advanced towards a work piece (W) in a pulsed fashion and having a voltage level which will provide a first current when contact between the electrode (107) and the work piece (W) is made. After contact the electrode (107) is retracted so that a welding arc is established and after the welding arc is established the current and wire feed speed is increased to a welding level.
Abstract:
A system and method for controlling a hybrid welding process. An integrated hybrid welding power source (100) includes a first power supply (200) for providing a first welding output and a second power supply (300) for providing a second welding output. The first power supply (200) and the second power supply (300) are operatively connected to coordinate the first welding output with the second welding output in real time while operating concurrently.