Incremental hybrid welding systems and methods

A welding system, comprising:

• an engine configured to drive a generator to produce engine power output, wherein the engine is rated below approximately 25 horsepower;
• an energy storage device configured to provide storage device power output;
• a charger coupled to the energy storage device and to the engine and configured to receive the engine power output from the engine and to charge the energy storage device with the received engine power output;
• and
• a controller configured to:
• control access to storage device power output from the energy storage device, to
• control engine power output from the engine and production of welding power output;
• control auxiliary power output by conversion of the storage device output and engine power output based upon a plurality of stepwise thresholds of commanded welding power
• command welding power output and auxiliary power output to be produced from one of the storage device power output alone, or the engine power output alone in response to a first and a second threshold of the plurality of stepwise thresholds;
• and
• command welding power output to be produced from both the both storage device power output and engine power output in response to a third threshold of the plurality of stepwise thresholds.

A welding system, comprising:

• an engine configured to drive a generator to produce engine power output, wherein the engine is rated below approximately 25 horsepower;
• an energy storage device configured to provide storage device power output;
• a charger coupled to the energy storage device and to the engine and configured to receive the engine power output from the engine and to charge the energy storage device with the received engine power output;
• a controller configured to:
• activate and deactivate the engine to access engine power output and to charge the energy storage device;
• control access to storage device power output from the energy storage device and engine power output from the engine;
• control production of welding power output and auxiliary power output by conversion of the storage device output and engine power output based upon a plurality of stepwise thresholds of commanded welding power;
• command welding power output and auxiliary power output to be produced from one of the storage device power output alone, or the engine power output alone in response to a first and a second threshold of the plurality of stepwise thresholds;
• and
• command welding power output to be produced from both the storage device power output and the engine power output in response to a third threshold of the plurality of stepwise thresholds.