Jiffy Welder

The Jiffy Welder is an automation assisted welder developed for making FCAW and GMAW fillet welds. It consists of a trackless, mechanized weld carriage with an integrated wire feed system.

Weld power is provided by the Lincoln Electric PowerWave S500 which is controlled by the Jiffy Welder’s process control system.

With the exception of weld carriage travel and wire feed, all axes of motion are manually adjusted.

To facilitate rapid assembly and disassembly and ease of transport, the Jiffy Welder is made up of a number of lightweight modules:

  • Universal carriage
  • Wire feeder

The operator’s pendant is used to set and adjust the weld and sequence parameters. This pendant can be kept in a mounted position on the carriage, or detached for handheld operation when desired. The pendant and the network of controller components in the Jiffy Welder’s distributed control system makes up the process control system.

The semi-automatic MIG and FCAW weld control system is modular in design to optimize weld process control while minimizing operator training. The system provides control of the weld carriage travel and all weld sequence parameters, which are easily set and adjustable from the operator’s pendant.

Weld process control is incorporated via several modules integrated into the weld system. A microprocessor, distributed I/O and master logic PCB are located within the carriage body while the motion control system for the travel axis is directly integrated into the motor.

The Jiffy Welder process control system requires no field calibration due to the use of a stepper motor and precision circuit design. The motor only needs to be programmed for the travel axis for repair and replacement to be complete.

System Specifications

Weight (minus wire spool and torch): 46.2 lbs.
Weight (including wire spool and torch): 54.8 lbs.
Weld Voltage Lincoln mode dependent (up to 41.5 volts)
Weld Current: Lincoln mode dependent (up to 550 amps)
Wire Speed: 50 – 900 inches per minute, 1 ipm increments
Travel Speed 0 – 100 inches per minute, 0.1 ipm
Pre-purge Time: 0 – 10 seconds, 1 second increment
Post-purge Time: 0 – 10 seconds, 1 second increments
Burn-back Time 1 – 200 milliseconds, 1 ms increments
Travel Start Delay 0 – 5 seconds, 0.1 second increments

System Motions

  • Carriage travel
  • Wire feed
  • Torch Height (Manual)
  • Cross Seam (Manual)
  • Torch Tilt (Manual)
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