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The choice of a welding power source depends upon the process of welding.
Our discussion will cover power sources that are used in MMAW and TIG
welding processes
The following are the types of welding power sources that can be differentiated
based on value based parameters.
Advantages:
1.Very low initial investment
2.Simple to use and service.
Disadvantages:
1.Very high no load current.
2. There is no control of current. Current is fixed, will also depends on the electrode
and input voltage.
3.Very inefficient.
4.Very low power factor.
5.Due to 1 and 2 draws very large current from the electricity establishment. (see the
table).
6.Due to 3 running cost is high.
7.Poor quality of weld.
8.Brute force of current.
9.Welding at low currents is not at all possible.
10.Bulky equipment, thus occupies large floor space.
11.Poor portability.
12.TIG / Argon welding not possible.
13.Welding of non- ferrous metals not possible.
14.Lower deposition rate and deposition efficiency.
4.A2. Variable current welding transformer (magnetic shunt type).
Moving core
or
Moving Iron
Advantages:
1.Very low initial investment
2.Simple to use and service
Disadvantages:
1.Very high no load current.
2.Very inefficient.
3.Very low power factor.
4.Due to 1 and 2 draws very large current from the electricity establishment. (see the
table).
5.Due to 3 running cost is high.
6.Poor quality of weld.
7.Better control of current compared to the previous type but not satisfactory.
8.Bulky equipment, thus occupies larger floor space.
9.TIG / Argon welding not possible.
10.Welding at low currents is not possible.
11.Poor deposition rate and efficiency
4.B2. Thyristorised welding rectifier.
Advantages:
1.Moderate initial investment
2.Simple to use.
4
This Dc voltage is taken as the input to the switching device through a high
frequency power transformer.
As this switching frequency is very high the size of this transformer becomes
very small compared to its counter parts.
This stepped down AC voltage is again rectified using fast recovery diodes.
Very large capacity devices are available, which are very rugged.
Very low frequency of operation, which is well within the audio range.
As the frequency of operation falls well in the audio range, welding is very
noisy.
Speed of current control is slow and hence a very low welding current is not
possible.
All the above Drawbacks are eliminated, but It requires bulky and inefficient
base drive, which is complicated and not suitable at high powers.
High power transistors are extremely expensive.
As the technology is advanced with IGBTs and MOSFETs there are no takers
for these devices in welding application.
Large capacity devices are not popular due to their cost and availability.
Only device available for large capacity power sources. Power loss is
comparable to MOSFETs at low powers and lesser at medium and higher
powers.
7. DESIGN TOPOLOGIES.
a. Resonant power sources.
b. PWM power source. (Pulse width Modulated)
7.a. Resonant power sources carry the disadvantage of large circulating current,
bulky size due to commutating circuits. Hence they are less efficient. They offer less
control bandwidth and hence wide variation of current is not possible. They produce
less electromagnetic interference. Hence they are old generation for welding
application. They are used at very high frequency typically 400KHz to 1000KHz in the
field of communications, where EMI is a serious concern.
7.b. PWM power sources are the choice of the day as they offer large and fast
control. EMI problem is suitably reduced using filters. They provide wide control of
current typically from 3 to 400A, which is a very wide range. They provide a great
opportunity to incorporate more features. The speed of correction is exceptionally
advantageous to control current surges which is a necessity in TIG welding
application. The PWM technique offers a smooth short circuit current control, a very
good arc re-striking capability. And hence it is the latest and best choice for welding
application.
7. HOW ARCRAFTS EQUIPMENT IS BETTER THAN OTHERS?
1.Designed for wider input voltage fluctuations.
2.Designed for wider ambient temperature fluctuations.
3.Protected for under voltage, over voltage, single phasing and over temperature.
4.As many features are provided as required by the customers choice.
5.Ther is no surge of current, starts from the set value of current.
6.Very large number of models to choose from.
7.Tried and tested for quality.
8.Indegeniously designed and hence easy serviceability.
Input voltage is 230V AC in the case of single phase and 415V AC in the case
of three phase input power supply. While comparing in an actual
measurements the input voltage and output voltage has to accurately
measured.
Parameter
Welding
Transformer
Welding
Rectifier
Welding
Inverter
No load current
4 to 5 A
4 to 5 A
0.3 to 0.5 A
0.2
0.2
0.99
No load power
400 to 500 W
400 to 500 W
50 to 100 W
Output power
3.84KW
3.84KW
3.84KW
Efficiency
0.6
0.6
0.9
Input power
6.4 KW
6.4 KW
4.27 KW
0.5 to 0.6
0.6
0.95
Input KVA
Input current
55 A to 46 A
14.8 A
6.3 A
51.2 KWH
51.2 KWH
34.16 KWH
12,800 KWH
12,800 KWH
8540 KWH
Rs 64,000
Rs 64,000
Rs 42,700
Rs 21,300
Rs 21,300
--
48 A
8.5 A
--
--
--
Rs 21,300
--
--
8.5A to 48A
--
--
6.1KVA to
11.0KVA
Therefore there is a saving of Rs 21,300 per anum if a machine is used for one year
for 250 days @ 8 hrs a day, that is 2000Hrs per anum. We can calculate the same for
the given number machines and hours used which will substantially reduce the cost
burden
Also we can calculate the saving in the installed capacity, which will also saves on
electricity bill.
This calculation is for 4mm electrode and for larger electrode sizes the savings will
further increase.