Vahid Nahani Muhammad Firdaus Venothkumar Theivinderan Reddy

Rectification the process of converting an alternating voltage or alternating current into direct voltage or direct current 2 types of rectifier
 

Constant Current Constant Voltage

Welding power supply - device that provides an electric current to perform welding Welding requires above 12000 amps which will take AC power from the utility mains and convert it to DC for the welder. Example :
 

Car battery Sophisticated

Welding machines - a constant current (CC) or constant voltage(CV). Output Voltage - maintain steady current while constant voltage machine will fluctuate its output current to maintain a set voltage. Shielded metal arc welding will use a constant current source and gas metal arc welding and flux-cored arc welding typically use constant voltage sources. Constant voltage it also possible with a voltage sensing wire feeder.

Transformer is used to for the welding power supply converts the high voltage and low current electricity from the utility (AC) mains into a high current and low voltage , typically between 17 to 45 volts and 55 to 590 amps

Primary side of transformer is connected to AC and the secondary part is connected to full wave diode rectifier and the output is dc power supply for welding.

Sometimes referred as metal inert gas (MIG). Semi-automatic or automatic arc welding process. Uses constant voltage supply Thus, change in arc length results in a large change in heat input and current. A constant voltage, direct current power source is most commonly used with GMAW

MIG arc welding power source has a secondary tapped transformer. It consists of a transformer, rectifier and output capacitor The step down transformer winding in primary and secondary side are separated, which means the output of transformer is isolated from the power line ground. The rectifier is a full wave bridge of silicon diodes output filter smoothest the secondary voltage to give a more consist weld.

switch is used to select step on the transformer mechanically can control the secondary output voltage rebus and reliable design the output voltage cannot be controlled remotely and input voltage fluctuations will affect the output. The output filter capacitor is sized on the basis permissible output ripple voltage the capacitor supplies the maximum output current I continuously and it charges up to the output voltage every 1/100 s for the full wave rectifier with 50Hz line frequency.

A bleeder resistor is connected across the output capacitor to discharge it when the supply is turned off and to remove the hazard of an unexpected voltage

overcome the effect of input fluctuations on the output The welding power source opposite maintains a constant output voltage using an SCR control circuit. rectifier that remains in non-conductive state, even when forward voltage is applied from anode to cathode, until a positive triggle pulse is applied to the gate and the SCR fires. rectifier that remains in non-conductive state, even when forward voltage is applied from anode to cathode, until a positive triggle pulse is applied to the gate and the SCR fires.

Two SCR s in this design are connected in anti-parallel at the input to the transformer primary allowing power to be controlled during each half cycle of the AC input.

requires fewer moving parts and it can be remotely controlled and voltage fluctuations at the input do not affect the weld output. poor efficiency and low speed of control. If the dV/dt is too large , the device will begin to conduct without a gate signal an will result in erratic circuit operation and potential device damage.

Since the advent of high-power semiconductors such as the insulated gate bipolar transistor(IGBT) it is now possible to build a switching power supply capable of coping with the high loads of arc welding. These designs are known as inverter welding units first rectify the utility AC power to DC; then they switch (invert) the DC power into a step down transformer to produce the desired welding voltage or current

The input power AC is rectified to DC using a power factor correction boost converter

A full bridge MOSFET power stage convert the voltage back to AC at high frequency typically 50Hz to 100Hz. The transformer steps down the voltage which is then rectified and smoothed at the output stage. high power conversion efficiency due to high frequency operation of the MOSFET bridge the size of the components can be greatly reduced specially the transformer and the output filter stage. component size is inversely proportional to the operating frequency invertor power source maintains a constant output voltage regardless of changes in line input voltage and output current

very quick response time to change in line and load and produce excellent arc characteristics delivering a true multi process capability switching speed is the most important criteria required to minimize switching losses.

Advantages
The main power transformer, which operates at 20,000Hertz is vastly more efficient than 60Hertz transformers, which means it can be much smaller and the huge advantage in weight and portability in favor of the inverter based arc welder machines

Advantages
There is another advantage of the inverter power supplies power cost. The inverter equipment is much more efficient than transformer equipment. The other significant advantage of inverter power supplies is that, by chopping up the incoming AC so finely, we end up with a very steady DC, without the typical 60 Hertz ripple. This results in a much smoother, more stable DC welding arc.

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