SYSTEMS AND METHODS FOR MITIGATING WELDING GUN DAMAGE IN PULSED ARC WELDING

Embodiments of systems (100, 160) and methods related to pulsed arc welding are disclosed. A robotic welding system (160), having a welding torch (130) with a contact tip, is configured to perform the following method: (a) generate and output a series of a determined number (N) of welding output pulses as a welding wire electrode (E) is fed toward a workpiece (W); (b) stop generating welding output pulses while allowing the welding wire electrode (E) to continue to be fed toward the workpiece (W) in an attempt to electrically short to the workpiece (W); (c) attempt to confirm that the welding wire electrode (E) has electrically shorted to the workpiece (W) within a determined error time period (Terror); and (d) repeat steps (a) through (c) if electrical shorting of the welding wire electrode (E) has been confirmed within the determined error time period (Terror), else, shut down the robotic welding system (160) to avoid damaging the welding torch (130).