Design And Construction Of An Inverter Type ARC Welding Machine
The design and construction of an inverter-type arc welding machine represent a sophisticated engineering endeavor that involves the integration of various key components. An inverter welding machine utilizes advanced electronic circuitry to convert input power into a high-frequency AC current suitable for welding applications. The pivotal elements in this innovation include the inverter circuit, transformer, and rectifier, all meticulously designed to ensure efficient power conversion. The inverter’s versatility allows for precise control of welding parameters, enhancing performance and enabling the machine to adapt to diverse welding tasks. Through careful engineering, the inverter welding machine achieves a compact and lightweight design, making it highly portable and suitable for both industrial and on-site applications. This technological advancement addresses the demand for more flexible and efficient welding solutions, catering to a broad spectrum of welding requirements while optimizing energy utilization.
Chapter 1
Introduction
1.1 The Background
1.2 Aims And Objectives Of The Project
1.3 Significant Of The Study
1.4 Limitation Of The Project
1.5 Project Report Organization
Chapter 2
Literature Review
2.1 History Of Arc Welding Machine
2.2 Process Of Arc Welding
2.3 Consumable Electrode And Non-Consumable
Electrode Methods
2.3.1 Consumable Electrode Methods
2.3.2 Non-Consumable Electrode Methods
2.4 Arc Welding Power Supplies
2.4.1 Transformer
2.4.2 Generator And Alternator
2.4.3 Inventer
Chapter 3
Methodology And System Analysis
3.1 Methodology
3.2 Design Methology
3.3 Design Analysis
3.3.1 Power Stage
3.3.2 Oscillator Stage
3.3.3 Power Amplifier Stage
3.3.4 Transformer
3.4 Design Specification
3.5 Components/Device Identification And Description
3.5.1 Ic Sg3524
3.5.2 Metal-Oxide Semiconductor Field-Effect Transistor (Mosfet)
3.5.3 Transformer
3.5.4 Diode
3.5.5 Resistor
3.5.6 Capacitor
3.5.7 Circuit Breaker
Chapter 4
System Design And Implimentation
4.1 Introduction
4.2 Design Of Transformer
4.5 Operating Principle Of Fig4.3
Chapter 5
System Testing And Integration
5.1 Testing
5.2 Test Plan And Test Data
5.2.1 Components Test
5.2.2 System Test
Chapter Six
Summary, Recommendation And Conclusion
6.1 Summary Of Achievement
6.2 Problems Encountered And Solution
6.3 Recommendation
6.4 Conclusion
Reference
INTRODUCTION
1.1 THE BACKGROUND
Welding is a way of heating pieces of metal using electricity or a flame so that they melt and stick together. It can simply be defined as the process of joining two or more pieces of metal to make the act as a single piece. This is often done by melting the work pieces and adding a filler material to form a pool of molten material that cools to become a strong joint. Because of its strength, welding is used to join beams when constructing buildings, bridges and other structures. Welding can also be used to join pipes in pipelines, power plants at the construction sites and in home appliance. Furthermore, welding is used in shipbuilding, automobile manufacturing and repair, aerospace applications. There are many kinds of welding which include arc welding, resistance welding, gas welding among others. Emphasis will be laid on arc welding because it is the most common type of welding as well as the main aim of this project.
Arc welding is the process of welding that utilizes an electrical discharge (arc) to join similar materials together. Equipment that performs the welding operation under the observation and control of a welding operator is known as welding machine. To solve the problem of weight and size of conventional arc
welding machine, it is necessary to design an inverter. The inverter provides much higher frequency than 50Hz or 60Hz supply for transformer used in welding. So transformer of much smaller mass is used to permit the handling of much greater output power. The welding noise produce by conventional arc welding machine is reduced by selecting the operating frequency over the hearing of human ability. The choice of 20Khz for the inverter type arc welding machine was determined to meet the above expectation. The output welding current is controlled by controlling the power supply for transformer at high frequency. This power supply is provided by a frequency inverter. Power switch IGBTs (Insulated Gate Bipolar Transistor) or MOSFETs is used for the inverter design due to its high switching. The control circuit use to control the output welding current is design to drive the power switch at high frequency. Insulated Gate Bipolar Transistor power switch is more efficient and less prone to failure than MOSFETs power switch.
1.2 AIMS AND OBJECTIVES OF THE PROJECT
The main aim and objective of this project is to design and build and arc welding machine that operates on 36vdc at variable frequency which of benefit to urban area. This reduces the weight and size of the transformer use for welding. To have an arc welding machine that is more efficient which produce neat welding.
1.3 SIGNIFICANT OF THE STUDY
The significant of this project is that it seeks to develop an arc welding machine that is cost effective, strong and portable. Not only that the arc welding machine is strong and portable, it is also mobile.
1.4 LIMITATION OF THE PROJECT
The project has certain limitations which are mentioned below.
This project cannot weld bigger gauge of metals.
The welding time and power depends on the battery input power.
You are to have bands of battery for reliability when using battery.
The machine must be used by a qualified welder. Welding can endanger the operator or people near the working area. Therefore, the performance of welding and cutting must only be done under the comprehensive observation of all relevant safety regulation.
Switch function modes during welding could potentially damage the equipment. A safety switch is necessary to prevent the equipment from electric leakage. Use only high quality welding tools and equipment with this inverter type arc welding machine.
1.5 PROJECT REPORT ORGANIZATION
The organization of the project report is well detailed and vast in its coverage. It covers all the activities encountered during the research work. The first chapter is the introductory chapter which covers the background, project objectives, project justification, and scope of the project. Chapter two presents the literature reviews. Chapter three covers the system analysis and design methodology in details. Chapter four presents the system implementation which entails the circuits diagram of different stages and also the complete schematic diagram with necessary calculation involve in the design. Chapter five is emphasis on conclusion, problem encountered during project design, recommendations and suggestion for further improvement. Fig1.1 depicts an overview of project report organization.
Introduction
Literature review
Methodology and system analysis
System Design and Implementation
System testing
Summary, recommendation and conclusion
Fig1.1 An overview of project report organization
SHARE PROJECT MATERIALS ON:
Design And Construction Of An Inverter Type Arc Welding Machine:
Designing and constructing an inverter-type arc welding machine is a complex task that requires a deep understanding of electrical engineering, power electronics, and welding processes. It’s important to note that building such a machine from scratch may involve legal and safety considerations, and it’s advisable to consult with professionals or experts in the field to ensure compliance with regulations and safety standards. Below is a simplified outline of the design and construction process:
1. Define Requirements and Specifications:
- Determine the type of welding (e.g., MMA, TIG, MIG) the machine will perform.
- Specify the required welding current and voltage ranges.
- Identify any special features needed, such as remote control, pulse mode, or dual voltage support.
2. Gather Components and Materials:
- Collect the necessary electrical components, including:
- Inverter circuit components (IGBTs, diodes, capacitors, etc.).
- Control circuit components (microcontroller or microprocessor, sensors, buttons, displays, etc.).
- Transformers, chokes, and heat sinks.
- Welding cables, connectors, and electrodes.
- Enclosure and cooling system components.
3. Design the Inverter Circuit:
- Choose a suitable topology for the inverter (e.g., half-bridge or full-bridge).
- Calculate component values based on the desired output current and voltage.
- Design the gate drive circuitry for IGBTs or MOSFETs.
- Include protection circuits (overcurrent, overvoltage, temperature).
- Ensure isolation between high-voltage and low-voltage sections.
4. Control System Design:
- Develop a control algorithm to regulate the welding current and voltage.
- Implement a feedback control loop using sensors (e.g., current and voltage sensors).
- Design user interface controls for setting parameters and monitoring.
- Develop safety features such as overheat protection and fault detection.
5. Build and Assemble:
- Assemble the inverter circuit on a PCB or custom-made circuit board.
- Connect the control circuitry and user interface components.
- Install transformers, chokes, and heat sinks as required.
- Ensure proper insulation and grounding.
6. Testing and Calibration:
- Perform initial tests for functionality and safety.
- Calibrate the control system to achieve the desired welding characteristics.
- Verify that safety features work correctly.
7. Enclosure and Safety:
- Build or install an enclosure to protect users from electrical hazards.
- Install cooling fans or a cooling system to prevent overheating.
- Apply warning labels and instructions for safe use.
8. Compliance and Certification:
- Depending on your location, you may need to comply with safety and regulatory standards.
- Consider seeking certification if you intend to sell or use the welding machine commercially.
9. Documentation:
- Prepare comprehensive documentation, including schematics, wiring diagrams, and user manuals.
10. Final Testing:
- Conduct extensive testing to ensure the machine meets specifications and safety standards.
Remember that designing and building a welding machine is a complex task, and safety is paramount. It’s crucial to have a thorough understanding of electrical and welding principles, as well as experience with power electronics. If you are not an expert in this field, it’s strongly recommended to consult with professionals or consider purchasing a commercially available welding machine that meets your needs.