A medium frequency transformer design for spot welding machine using sizing equation and finite element analysis

Arslan, Serdal; Tarımer, İlhan; Güven, Mehmet; Oy, Sibel Akkaya

doi:10.30765/er.40.3.05

Cited by 2 publications

(2 citation statements)

References 14 publications

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“…A HFT optimization design to exploit the utilization of the transformer to achieve high power density with minimum transformer loss has been reported in [22]. Recently, a medium frequency transformer design has been proposed based on open-source optimization framework where the magnetic field calculation is done by a built-in FEM solver [23,24].…”

Section: Literature Backgroundmentioning

confidence: 99%

Optimal design of minimal footprint high frequency transformer

Banumathy¹,

Veeraraghavalu²

2021

Serb J Electr Eng

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Transformer design procedure may vary essentially in respect of the transformer type and its operating frequency (ranging between 50/60 Hz and a few megahertz). This paper presents a simple and straightforward method based on the optimal choice of core geometry of a high frequency transformer (HFT) used in Solid State Transformer (SST) applications. The core of SST is the HFT which largely influences its size and overall performance. The proposed design procedure for HFT focuses on optimizing the core geometry coefficient (in cm5) with a constraint inflicted on loss density. The core geometry coefficient has direct impact on the regulation and copper loss and the procedure results in a robust overall design with minimal footprint. Also, the procedure intends to bring all the operating parameters like regulation, losses and temperature rise within permissible limits while retaining desired efficiency. Thus an energy-efficient design is achieved with minimal footprint. The optimization procedure is implemented using recently developed Moth-flame Optimization (MFO) algorithm. The results of the MFO algorithm are compared with the wellestablished PSO technique. An experimental prototype is built to validate the findings.

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Section: Literature Backgroundmentioning

confidence: 99%

Optimal design of minimal footprint high frequency transformer

Banumathy¹,

Veeraraghavalu²

2021

Serb J Electr Eng

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“…The conduction states of the IGBTs are controlled by the welding timer. This control is based on an SMPS (phase-shifted full-bridge); therefore, to control the energy supplied to the welding point, the welding timer modifies the duty cycle of the SMPS [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Incipient Wear Detection of Welding Gun Secondary Circuit by Virtual Resistance Sensor Using Mahalanobis Distance

Ibañez

García²,

Soret

et al. 2023

Sensors

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Wear of the secondary of the welding gun, caused by mechanical fatigue or due to a bad parameterization of the welding points, causes an increase in quality problems such as non-existent welds or a reduced weld nugget size. In addition to quality problems, this defect causes production stoppages that affect the final cost of the manufactured part. Different studies have focused on evaluating the importance of different welding parameters, such as current, in the final quality of the welding nugget. However, few studies have focused on preventing weld command parameters from degrading or changing. This investigation seeks to determine the wear of the secondary circuit to avoid variability in the current supplied to the welding point caused by this defect and the increase in circuit resistance, especially in industrial environments. In this work, a virtual sensor is developed to estimate the resistance of the welding arm based on previous research, which has shown the possibility of detecting secondary wear by analysing the duty cycle of the power circuit. From the data of the virtual sensor, an anomaly detection method based on the Mahalanobis distance is developed. Finally, an integral system for detecting secondary wear of welding guns in real production lines is presented. This system establishes performance thresholds based on the analysis of the Mahalanobis distance distribution, allowing monitoring of the secondary circuit wear condition after each welding cycle. The results obtained show how the system can detect incipient wear in welding guns, regardless of which part of the secondary the wear occurs, improving decision-making and reducing quality problems.

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A medium frequency transformer design for spot welding machine using sizing equation and finite element analysis

Cited by 2 publications

References 14 publications

Optimal design of minimal footprint high frequency transformer

Optimal design of minimal footprint high frequency transformer

Incipient Wear Detection of Welding Gun Secondary Circuit by Virtual Resistance Sensor Using Mahalanobis Distance

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