Design and development of improved power quality based micro‐butt welding power supply

Abstract

This study proposes a suitable DC-DC converter topology with improved power quality at the input side for micro-butt welding machine by evaluating different power factor correction (PFC) techniques and DC-DC converter topologies. Firstly, different control strategies of boost converters such as peak current controlled PFC, average current controlled PFC and hysteresis current controlled PFC are discussed for minimising input current distortions and improving the power quality. Also, the current loop gain stability analyses are presented using small-signal model for selecting the best model and optimisation of the same. Secondly, the important key parameters such as cost, size, weight, complexity in implementation and other application dependent parameters of various isolated type of DC-DC converter topologies are compared and the best DC-DC converter topology is selected for the proposed application. Finally, the modelling and stability analysis is performed on the DC-DC converter and optimisation is achieved for the welding current controller. The software packages MATLAB/Plecs/OrCAD PSpice are used for simulation and implementation of the desired circuitry with optimised design. A prototype has been developed based on optimised design, hysteresis current controller for PFC and DC-DC converter; and the control algorithm is implemented DSP TMS320F2812 and the experimental results were discussed. 2 DC-DC converter topologies for micro-butt welding The DC-DC converter consists of inverter, high frequency transformer (HFT), rectifier and filter. The primary requirements of welding power supply are galvanic isolation from main supply, DC current (150-600 A) regulation with max of 5 V and capability to withstand during the short-circuit condition. The general criteria for selection of DC-DC converter are cost, weight, size and ease of

Single-phase front-end bridgeless modified Landsman-Canonical Switching Cell PFC converter for arc welding applications

“…The merits of this converter include good power quality, high PF, and low inrush current under different load conditions. Moreover, the PQ indices of the PFC converter meet the specifications of an International Standard IEC 61000-3-2 [2][3][4][5]. Numerous converters for arc welding power supplies were compared on the basis of the aforementioned attributes and are reported in the literature [1][2][3][4][5].…”

Power quality improvements of arc welding power supplies by modified bridgeless SEPIC PFC converter

“…To overcome these drawbacks, active PFC is introduced as a pre-regulator to comply with PQ requirements and international standards such as EN 61000-3-2 and IEEE 519-1992 [3]. PFC converter-based AWPSs have been explored in the literature [4][5][6]. However, the important requirements of an AWPS have led to the development of power converters suitable for AWPSs such as interleaved canonical switching cell [1], bridgeless boost converter [2], modified zeta converter [4], and canonical switching cell [5].…”

Real time assessment of power quality issues in 11 kV/440 V distribution feeder using distribution static synchronous compensator

“…The distribution system paved way to have a steep increase in PQ issues. One of the main non-linear loads is which will induce voltage disturbances results in degraded quality of power (Madhulingam et al, 2017). The arc furnace operation induces high flicker level in the distribution system (Maksi et al, 2016).…”