Lincoln Global, Inc.

Judah B Henry

Daniel P Fleming

Steven R Peters

Joseph Allen Daniel

James Hearn

William Thomas Matthews

Badri K Narayanan

Edward Dennis Hillen

Jonathon C Kelm

Tamara Savrin

Edward A Enyedy

Bruce John Chantry

Stephen R Cole

Matthew R Pischel

A shielded metal arc welding system includes a stick electrode holder, a stick electrode clamped by the holder, and a welding power supply operatively connected to the holder and configured to supply a welding current to the electrode through the holder. The power supply includes a memory storing both of a short circuit threshold voltage level and an arcing threshold voltage level. A welding voltage level is detected during an initial shorting of the electrode to a workpiece for commencing a welding operation. Both of the short circuit threshold voltage level and the arcing threshold voltage level are adjusted based on the detected welding voltage level. A short circuit clearing routine is activated when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level, and deactivated when the welding voltage level is equal to or greater than the adjusted arcing threshold voltage level.

Arc welding adjustable short circuit threshold

A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.

System and method for adapting break point for short circuit welding

A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Real time resistance monitoring of an arc welding circuit

A method of preventing arc flaring events for a welding system is provided. The method includes determining, by a controller, a real-time welding output characteristic of the welding system. The method additionally includes comparing, by the controller, the real-time welding output characteristic to a threshold welding output characteristic. The method further includes controlling an operating characteristic of the welding system in response to a determination that the real-time welding output characteristic exceeds the threshold welding output characteristic.

Tip saver for a welding system

Embodiments of systems and methods in pulsed arc welding. A robotic welding system, having a welding torch with a contact tip, is configured to perform the following method: (a) generate and output a series of a determined number of welding output pulses as a welding wire electrode is fed toward a workpiece; (b) stop generating welding output pulses while allowing the welding wire electrode to continue to be fed toward the workpiece in an attempt to electrically short to the workpiece; (c) attempt to confirm that the welding wire electrode has electrically shorted to the workpiece within a determined error time period; and (d) repeat steps (a) through (c) if electrical shorting of the welding wire electrode has been confirmed within the determined error time period, else, shut down the robotic welding system to avoid damaging the welding torch.

Welding system for mitigating gun damage in pulsed arc welding

Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

System and method providing rapid decay of peak pulse current

A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Dual wire welding or additive manufacturing system and method

A welding system is provided which utilizes a short arc welding method in which the waveforms have a positive polarity portion and negative portion to optimize heat input and provide heat and current control.

Apparatus and method for welding with AC waveform

The invention described herein generally pertains to a system and method for welder system that relates to creating a welding sequence for a welding environment in which the welding sequence is based upon real time data collected from a performed or previously performed welding procedure. Welding procedure information is collected and utilized to create a welding sequence to perform two or more welds in which at least one parameter is based on the collected welding procedure information (e.g., real world welding procedure).

System and method for creating or modifying a welding sequence

The invention described herein generally pertains to a system and method for welder system that relates to creating a welding sequence for a welding environment in which the welding sequence is based upon non-real time data collected from a welding procedure. Welding procedure information is collected and utilized to create a welding sequence to perform two or more welds in which at least one parameter is based on the collected welding procedure information (e.g., non-real world welding procedure).

System and method for creating or modifying a welding sequence based on non-real world weld data

Embodiments of the present invention are directed to systems and methods of controlling wire feeding in a welding operation, where the wire feeding has a plurality of positive and negative pulses. Embodiments determine an average wire feed speed and compare the average to a desired wire feed speed and then change a parameter of the wire feed pulses to achieve a desired wire feed speed.

System and method for arc welding and wire manipulation control

An electric arc welding system and method includes providing a welding apparatus having at least a welding power supply, a wire feeder configured to supply a welding wire, a welding gun having an opening from which the welding wire extends, and a welding controller. The controller can initiate a weld ending process, which senses any contact between the welding wire and a workpiece. In response to any such contact, the controller executes a wire material transfer routine to transfer molten material of the welding wire from the welding wire to the workpiece. This routine can be repeated until the wire feeder stops advancing the welding wire towards the workpiece during the weld ending process.

Weld ending process and system

An arc welding system includes a welding torch, an electrode, and a power supply having a switching-type power converter connected to the torch. A parallel state-based controller is connected to the power converter and provides a waveform control signal thereto for controlling its operations. The controller generates a motion control signal for controlling movements of the electrode and/or the torch. A sensor senses welding voltage or welding current. A memory stores a welding state table comprising sequential control states, and stores a motion control system state table comprising further sequential control states. The welding waveform is defined in the welding state table. The controller controls the operations of the power converter through the waveform control signal according to the welding state table, simultaneously adjusting the motion control signal according to the motion control system state table. The controller transitions between control states according to the signal received from the sensor.

Parallel state-based controller for a welding power supply

A welding system comprises a welding power source that provides an alternating current in a selected wave form having a set of positive and negative portions, the negative portion consisting of a peak, tailout, and background phase, and the positive portion consisting of a peak, tailout, and background; wherein the power source provides an upward ramping current during the pinch and detachment phase, switches to an electrode negative current during the negative peak, tailout, and background phases, and switches to a subsequent electrode positive portion; wherein, the positive portion may repeat prior to the next shorting event.

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Painesville, OH, United States of America

Judah B Henry