CHAPTER 1

ARC WELDER
1.1 INTRODUCTION
This is a transformer type arc welder that will transform incoming high voltage, low amperage
electricity into high amperage, low voltage welding current. An arc welder should be on a separate
circuit of its own with a 50 amp. Breaker and in our welding transformer it will take from power
supply 220volt and 3 amps no load current and it give output of 200 amp range current and 40 volt
at output terminals. And it melts the 8 no. rod to weld any metallic surface. The diagram of the
transformer is shown as below.

FIGURE1.1: ARC WELDING MACHINE

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CHAPTER 2

MATERIAL REQUIRED

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

MATERIAL

QUANTITY

TRANSFORMER CORE
WINDING CONDUCTOR
INSULATING PAPER
COTTON TAPE
PVC TAPE
SLIP
NUTS AND BOLTS
VARNISH
BAKELITE SHEET
LUX
INDICATOR
HOLDER
HOLDER LEAD
PVC CABLE
WELDING RODS
CLAMPS
PLIER
CUTTER
SCREW DRIVER
WRIENCH
HAMMER
SCISSOR
CLAMP METER

SIZE (9 X 2 & 5 X 2)
SWG (10 & 4)
CLASS B
1 INCH
1
4
16
500 ML
12 INCHES
4
1
1
10 MM (2 METERS)
6 MM (3 METERS)
8, 10&12 NUMBERS
4(12 X 2)
1
1
1
2(10-12, 14-15)
1( 200 GRAMS)
1
1

CHAPTER 3

CONSTRUCTION AND DESIGN OF WELDING

TRANSFORMER
3.1. CORE

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The performance of a transformer mainly depends upon the flux linkages between the
windings. For efficient flux linking between the windings, one low reluctance magnetic
path common to all windings should be provided in the transformer. This low reluctance
magnetic path in transformer is known as core of transformer.
We used an insulated metal strip (CRGO) of size 92 and 52 for a construction of a core
of a transformer. The size of the core of transformer is 9 of length and 9 inches of
breadth. The weight of a whole transformer core is 14.5 kg. The construction of core is
shown in the figure 2.1 below.

FIGURE 3.1: CORE OF TRANSFORMER (TOP VIEW)

In this we made a core type construction for a transformer, in which we placed two coils in
each of the vertical leg of the core. When these lamination stampings is connected together
form the required core shape as shown in above figure2.1 and their side view of core also
shown in the figure2.2.

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FIGURE 3.2: FRONT VEW OF CORE

3.2 COILS CONSTRUCTION

The conducting material used for the windings depends upon the application, but in all
cases the individual turns must be electrically insulated from each other to ensure that the
current travels throughout every turn. The coils used for this transformer are form-wound
and are of cylindrical type. The cylindrical coils will have different layers and each layer
will be insulated from the other with the help of materials like paper, cloth, etc.
2.2.1. Primary winding:
The transformer's primary winding creates a varying magnetic flux in the core and a
varying magnetic field affect on the secondary winding. This varying magnetic field at the
secondary induces a varying electromotive force (EMF) or voltage in the
secondary winding.
For the construction of primary winding coil DCC conductor is used, which come in
different size. For the primary coil we use 2.4 kilograms of 10 SWG aluminium DCC
conductors. The coil made by wrapping the conductors in a cylindrical form layer by layer.
Paper is used to insulate the different layers of the coil.

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In the primary winding coil there is 125 numbers of turns in each coil.there are fours
tapping is available in primary coil in every 24 turns.
No. of turns in primary coil each, N1 =125

FIGURE 3.3. PRIMARY COIL FIXED ON A CORE

3.2.2. Secondary Winding

The secondary winding that provides the output to the load or loads. The flux, produced by
primary winding, passes through the core, will link with the secondary winding. The same
aluminium DCC conductor used in primary winding coil Is also used in secondary winding
coil. But size of the conductor for secondary winding is different. We use 2.4 kilograms of
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4 SWG alluminium DCC conductors for secondary side coil. We made two coils for
secondary side of transformer. The each coil having a 38 number of turns.
No. of turns in secondary coil each, N2=38

FIGURE 3.4 SECONDARY WINDING FIXED ON A CORE

CHAPTER 4
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CONNECTIONS
The connection of the welding transformer done in series connection. The coil is arranged
over the core in alternate form. In the first leg placed primary coil, then the secondary coil.
Similarly on the another leg put secondary coil first then primary coil over the secondary.
These coil insulated from each by using a insulated paper.

FIGURE 4.1: SERIES CONNECTION OF TRANSFORMER

FIGURE 4.2: FINAL VIEW OF CONNECTION

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CHAPTER 5

SPECIFICATIONS AND COST

5.1DESCRIPTION:
180 amp air cooled arc welder.
1) Input voltage / phase: 220 volt / 1
2) Current input: 3 amps 27 amps
3) Current output: 70 amps 180 amps
4) Voltage output: 20.8 volt 25.2 volt
5) Welding rods recommended: 1 mm 3 mm
6) Dimensions (Length X Breadth X Height) : 14 X 12 X 14.
7) Weight: 20KG.

5.2 COST
MATERIAL

COST (RS.)

CORE

1200

CONDUCTOR

1500

ELECTRODE HOLDER

200

HOLDER LEAD

260

PVC CABLE

50

BAKELITE SHEET

60

VARNISH AND PAPER

250

COTTON TAPE

140

LUX

40

OTHERS

500

TOTAL COST

4200

CHAPTER 6
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SURVEY
6.1. TRANSFORMER INDUSTRIES IN JAIPUR
1. Uttam Bharat Electricals Private Limited
Road no. 9F, V.K.I Industrial Area Jaipur Rajasthan
2. Indian Transformer Electrical
Road no. 17, V.K.I Industrial Area, Jaipur, Rajasthan.
3.Shree Transformers
V.K.I Area, Jaipur, Rajasthan
4. Swastik Copper Private Limited
Sitapura Jaipur,Rajasthan

6.2. WELDING TRANSFORMER DEALER IN JAIPUR

1. Anil Electrical,
M.I Road, Jaipur ,Rajasthan.
2. Maheshwari Electrical
Mi Road, Jaipur, Rajasthan
3. Avishkar Traders
Shansar Chand Road, Jaipur, Rajasthan.

6.3. RATE LIST

s. no.

Brand name

Type

rating

Cost(Rs.)

1.
2.

Primeir
Hi-tech

4 coil
4 coil

50-200amp
70-250amp

5500
6200

3.

Vulcan

4 coil

55-200amp

5800

6.4. COMPARATIVE ANALYSIS

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Brand

Primeir

Hi-tech

Vulcan

Our welding

Type
Rating(amps)
Cost(Rs.)

4-coil
50-200
5500

4-coil
70-250
6200

4-coil
55-200
5800

machine
4-coil
70-200
4200

CHAPTER 7

ADVANTAGE AND DISADVANTAGE

7.1. ADVANTAGES
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Versatility - readily applied to a variety of applications and a wide choice of

electrodes

Relative simplicity and portability of equipment

Low cost

Adaptable to confined spaces and remote locations

Suitable for out-of-position welding

7.2. DISADVANTAGES

Not as productive as continuous wire processes

Likely to be more costly to deposit a given quantity of metal

Frequent stop/starts to change electrode

Relatively high metal wastage (electrode stubs)

Current limits are lower than for continuous or automatic processes (reduces
deposition rate)

CONCLUSION
Welding is a fabrication process that joins materials; usually metals. This is often done by
melting the work-piece and adding a filler material to form a pool of molten material (the
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weld pool) that cools become a strong joint. The melting is achieved with pressure
sometimes used in conjunction with heat, to produce the weld. Different power supply can
be used for welding. Arc welding machine transform low voltage low amperage primary
power into the low voltage, high amperage power used for welding at high frequency. This
high frequency transformation helps to reduce the weight and size of the transformer.
The samples were characterized by means of tensile strength, hardness and elongation.
From the investigation it is found that an increase in welding speed increases the tensile
strength and increase in tool rotation speed, decreases the tensile strength.
Welding means the permanent joining together of components by means of heat or
pressure, with or without welding additives. It has specialized in arc welding, one of the
oldest electrical welding processes for metallic materials. This arc between a consumable
electrode as additive material and the work piece, functions as a heat source when welding.

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