Illinois Tool Works Inc.

Charles Lyle Kaufman

Michael Todd Klegin

Mark Andrew Ulrich

Chris John Roehl

Indra Budiman Wiryadinata

James Lee Uecker

Robert Raimund Davidson

Jeffery Ray Ihde

Albert Matthew Nowak

Brandon John Speilman

Gary L Scheelk

A welding power source configured to receive an input power includes a plurality of components and supervising circuitry configurable in a plurality of modes. The plurality of components include power conversion circuitry and background power supply. The supervising circuitry is configured to distribute the input power to the plurality of components based at least in part on a mode of the plurality of modes. The plurality of modes include a welding mode configured to distribute the input power to the power conversion circuitry and to the background power supply. The plurality of modes also include a monitoring mode configured to distribute the input power to the background power supply, and to not distribute the input power to the power conversion circuitry.

Power source for reducing electromagnetic interference and power consumption

A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Method and system of welding with auto-determined startup parameters

A system and method for stabilizing a welding arc is disclosed. The method of initiating the arc includes the steps of defining a wire feed speed based on a user selected wire feed speed and then abruptly reducing the wire feed speed before the wire feed speed reaches a relatively stabilized speed for welding, thereby allowing a welding arc to initiate and propagate to a generally steady state.

Welding arc stabilization process

A hybrid wire feeder including an energy storage device and a charging circuit are provided. The hybrid wire feeder may selectively alternate between utilization of power from the energy storage device and utilization of power from a welding power supply to power the weld and one or more weld sequencing events. Some embodiments provide for the energy storage device to be adapted to discharge during periods when the welding power supply is not outputting power and to recharge from the welding power when the welding power supply is outputting power.

Hybrid wire feeder systems and methods

A welding system, in certain embodiments, includes a synchronization controller configured to override a first nominal calibration of a first wire drive, or a second nominal calibration of a second wire drive, or both, in response to a tension condition or a compression condition of a welding wire feeding between the first and second wire drives. A welding system, in other embodiments, includes a welding wire drive having a motor, a controller, a nominal calibration, and a multi-drive synchronization parameter. The multi-drive synchronization parameter may be configured to control speed, or torque, or both, of multiple drives including the welding wire drive to facilitate synchronization of the multiple drives.

Synchronized multiple drive wire feed welding system and method

A welding system including a welding power supply coupled to a wire feeder via a spool gun connection is provided. The welding system is adapted to utilize the power and control capabilities originating from the spool gun connection for wire feeder operations during an initial period. The wire feeder is adapted to utilize the welding arc power and an internal controller to power and control wire feeder operations after the initial period.

Welding systems and methods for controlling a wire feeder via a spool gun connection

The present invention is directed to a system and method of automatically adjusting the operating parameters of a welding-type system based on the type of welding being carried out. The invention includes a controller that is configured to automatically delineate between a tacking and a welding mode of operation. The controller is also designed to decrement a timer at the onset of a welding event and if the timer expires before the welding event is complete, then automatically enable a crater fill control feature of the welding-type system being used to support the weld event. If the timer has not expired when the weld event is terminated, then the controller automatically disables the crater fill control features and prevents the delivery of post-weld event termination filler to the weld or maintenance of a welding power at the weld sufficient to melt a consumable electrode.

Method and system of welding with adaptive crater fill control

The present invention is directed to an apparatus and method for controlling a wire feeder. The wire feeder includes a wire feeder motor configured to drive delivery of a welding wire at an actual wire feed speed (WFS) according to a welding-type process. The wire feeder also includes a processor configured to adjust motor calibration parameters such that actual WFS matches a desired WFS.

System and method for calibrating wire feeder motor control

A process is disclosed that monitors a characteristic of a welding gun connected to a wire feeder and, based on the detected characteristic, automatically determines the type of gun connected and sets operating parameters of the wire feeder and/or welding gun accordingly.

Method and apparatus to automatically determine type of gun connected to a wire feeder

The present invention is directed to an apparatus and method for coordinating wire feeder motor operation. A wire feeder system includes a push motor configured to push a welding wire at a desired speed to and a pull motor configured to pull the welding wire from the push motor and dispense the welding wire from the wire feeder system. The system also includes a controller configured to control the pull motor to pull the welding wire at a start speed greater than the desired speed during a startup period.

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Neenah, WI, United States of America

Charles Lyle Kaufman