Welding Processes

- .

Welding Power Supplies

& Controls

Lecture 6 p
Lecture Scop_e _ (

• Power Supply Output Characteristics

• Relationship to Welding Processes
• Main Types of Power Supply
- Transformer
- Solid state
- Alternator

• Process Controls

p2
 "Drooping" Output Characteristic

BOV Open Circuit Voltage

,
i !
lOA -...i!
, I
Change in Current

150 A Maximum Current

CURRENT (AMPERES)

Lecture 6
"Flat" Output Characteristic (

UJ
(!)

~
:.J
o
>

vI r=--=::C:~J~L~o:ng~N~C;_~~~~
rtNC
Open Circuit Voltage 30 V
Change in Voltage 5 _-.-! _ _ _ _ _ Sho -
I ~
, I
I ,
i Change in Current I
,
I •
100A i
• ,
100A 200 A
. CURRENT (AMPERES)

p4
 Combination Volt-Amp Curve

w
C)
~
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o
>

CURRENT (AMPERES)

Lecture 6 p~
 Principal Elements of
TransformerPowerSu~ __ (
N1 N2
TURNS TURNS
A C

AC
ARC
OUTPUT

,--_J
METAL CORE
TRANSFORMER
A: Primary solid state inverter if used
B: Series output control if used (AC/DC)
C: Rectifier or SCR control for DC output
D: Secondary switch for chopper type control of DC output

,6 p6
 Moveable-Coil AC Power Source
PRIMARY
COIL

IRON
MINIMUM
CORE v
OUTPUT
SECONDARY
COIL o 50 100 1m 200 250
A

80

v
G 50 100 150 200 250
A

lecture 6 p'
.Jlpical Series Impedance Control (

,...............
: . __ - __ ..
,,
• ,!,
r i
Ex
~?~r.~9.~...r:>~?P., -
SERIES i
-
-

•1 ,, 1 !' IMPEDANCE .li

i...............___...........__.......__ t
, i
AC Output Arc
Input !TRANSFORMERI Voltage Voltage ARC
Voltage ,1,, Eo EA
,,j
•
I i •
,
, ~ +
[..__ __ .1

p8
 Moveable-Core Reactor AC
Power Source

POSITION FOR POSITI6N FOR

MINIMUM CURRENT MAXIMUM CURRENT
TRANSFORMER

PRIMARY SECONDARY
COil COil

I L-_-..l..../
.... -----"'""'1/
MAGNETIC FLUX PATH
ELECTROD
STATIONARY SECTION

lecture 6 p!
 Saturable Reactor AC Welding
Power Source (

DCCONTROL
c ..
-
I -
- I I I I T\ \ T

AIR GAP ·rt I \ I , I , I

= . AIR GAP

I
--..... --
e>-
,...j
- --Iw_ ELEcTRODE]
WORK I

WELDING
TRANSFORMER

6 P 10
 Magnetic Amplifier Control
+
DC CONTROL INPUT l~
-
Lr' I I ,

fl.,T \\\ , -
-

i>~
OIO~E
.. CONTROL
I Ie - COILS

TRANSFORMER
~'~J V WEL DING

ACPRIMARY --
'-- -- .
AC SECOt:!OARY
I
\ I I

.,
ELECTRODE

I
0- - -Iw- WORK

Lecture 6 P 11
 AC Current Waveforms (

ELECTRODE NEGATIVE

A
ELECTRODE POSITIVE

ELECTRODE NEGATIVE

B
ELECTRODE POSITIVE

A-Magnetic Amplifier
B-Square Wave

,6 P 12
 Phase Control Using an SCR BridQ!

..
c:
~::r
o TIme
High-power SCRs conducting early in the half-cycle

..
c: /'
,--....
\.
~ •
I
c3 • TIme

Lower power SCRs conducting late in the half-cycle

Lecture6 p13
 SCR-Controlled DC Power Source (

- +
1
DC ARC
OUTPUT

1
AC
j
INPUT

I Z

6 p14
 Inverter Power Source

~oN\ ~ ~ JllIIlll o~'_

OUTPUT
INPUT BRIDGE BRIDGE
RECTIFIER INVERTER TRANSFORMER RECTIFIER INDUCTOR

AC -
INPlIT
-
-«-
1-.-
~~
-- I-- ]~ -cI- LuJ 0
+
utput

Inverter
Con1rOl
Circu~

Lecture 6 P 1,
 Alternator TY'pe Power SUe.e!Y_ _ (

COARSE CURRENT·
CONTROL
(TAPPED REACTOR)

AC HERE

IIIIM...-..r-
FINE CURRENT CONTROL DC OUTPUT

{
,

6 p16
 Process Controls

• Welding Current Programming

- upslope, downslope, crater fill

• Process cycle control

- co-ordinate operation of welding power, wire feed, weld
head motion, shielding gas flow, etc
- Open loop logic

• Adaptive or feedback control

- seam tracking
~ arc voltage control, electro-mechanical & optical
methods
- process control

Lecture 6 p1
 Current Programming _ (

Pulsed GTAW

pulse duration 0.1 - 1 sec

Peak
,-- ~ 00 current
~.I'ho
~~ Background
'-- ---.J l.... current
TIME

,6 p18
 Process Control
Component Status

SEAM
Weld overtap
Tracking
,
Cycle start
Weld Cycle TIme

,
Cycle end

TRACKER
Drive InlO~
Idle

Motion
TURNTABLE
Idle

Welding ClOTenl
WELDING
EQUIPMENT Shield gas flow
Idle

Lecture 6 pH
 Adaptive Control (

-
-
Input
variables <r Welding
Process
~ Output
variables

Feedback Loop

l p20
 Adaptive control
Arc length control based on arc voltage

L
-

Lecture 6 p2
 (
Adaptive Control
Joint tracking using arc voltage sensing

p22

- - - .. - -----
Adaptive control
Optical joint tracking method
Vldlo SIOllOI 10
,'-'...... 1oI0chlni lillian Sylt.m

:n~om.,o
~-INarraw
"
Band
Int.rfer.nce FllIlr
\
\.
.....
[JU
~;;:;;~

"-
C,llnclrlca1
Lenl .-Comlra ",;==='-'
....
Struclurad L10h
I
'V"'.-'
Optic AILII Monitor
(Laee, Plalllle:::~~Q.

p23
 (
Adaptive control

Feedback
control of
GTAWweld
penetration
based on
photodiodes

p24