200 Amper, Yüksek Frekans Anahtarlamalı DA Kaynak Makinesinin Tasarımı ve Gerçeklestirilmesi / Design and Implementation of a 200 Ampere High Frequency Switching DC Welding Machine

Year 2012, Volume: 2 Issue: 3, 51 - 61, 09.10.2012

Timur Aydemir Arzu Koparan Oğuz Şimşek

Abstract

Özet

Bu makalede, 5.6 kW (200 A) gucunde bir ark kaynağı makinesi icin yuksek frekans anahtarlamalı guc donusturucu devresi ve bu devrenin denetleyicisinin tasarımı ve gerceklestirilmesi anlatılmaktadır. Guc devresinde ikili ileri (dual forward) DA/DA donusturucu topolojisi kullanılmıstır. Modulerliği sağlamak icin iki adet donusturucu girisleri seri cıkısları paralel olacak bicimde bağlanmıstır. Makalede, tasarım sureci ayrıntılı olarak anlatılmakta, benzetim sonucları ve gerceklestirilen prototip devreyle elde edilen deneysel sonuclar verilmektedir.

Abstract

Design and implementation of a high frequency switched dcdc converter and its controller for an arc welding machine with a power rating of 5.6 kW (200 A) is described in this paper. Dual forward DC-DC converter topology has been used in the power circuit. Two identical converters have been connected in series input, parallel output structure to obtain modularity. Design of the converter is given in detail as well as the simulation results and experimental results obtained with the prototype converter.

 

Keywords

Evirici Tip Kaynak Makinesi, İkili İleri DA-DA Dönüştürücü, Inverter type welding machine, Dual forward DCDC Converter

References

• Bayindir, N.S., Kukrer, O., Yakup, M., “DSP-based PLLcontrolled 50-100 kHz 20 kW high-frequency induction heating system for surface hardening and welding applications”, IEE Electric Power Applications, Volume 150, Issue 3, 365 – 371, 2003.
• Pollock, H., Flower, J.O., “Design, simulation and testing of a series resonant converter for pulsed load applications”, Fifth International Conference on Power Electronics and Variable-Speed Drives, 1994, 256 – 261.
• Frohleke, N., Mundinger, H., Beineke, S., Wallmeier, P., Grotstollen, H., “Resonant transition switching welding power supply”, 23rd International Conference on Industrial Electronics, Control and Instrumentation, Volume 2, 1997, 615 – 620.
• Theron, P.C., Ferreira, J.A., Fetter, J.C., Koertzen, H.W.E., “Welding power supplies using the partial series resonant converter”, International Conference on Industrial Electronics, Control, and Instrumentation, 1993, vol.2, 1319 – 1324.
• Pollock, H., Flower, J.O., “Series-parallel load-resonant converter for controlled-current arc welding power supply”, IEE Electric Power Applications, Volume 143, Issue 3, 211 – 218, 1996.
• Dede, E.J., Esteve, V., Jordan, J., Gonzalez, J.V., Maset, E., “On the design and control strategy of high power, high frequency converters for tube welding applications”, Power Conversion Conference, 1993, 257 – 264.
• Wu, T.-F., Yang, H.-P., Pan, C.-M., “Analysis and design of variable frequency and phase-shift controlled series resonant converter applied for electric arc welding machines”, 21st International Conference on Industrial Electronics, Control, and Instrumentation, 1995., Volume 1, 656 – 661.
• Zeng, X.M., Parker, A.B., Lucas, J., “High-frequency TIG-welding power supply with microprocessor control”, IEE Proceedings Science, Measurement and Technology, A, Volume 137, Issue 4, 184 – 192, 1990.
• Pollock, H., Flower, J.O., “New method of power control for series-parallel load-resonant converters maintaining zero-current switching and unity power factor operation”, IEEE Transactions on Power Electronics, Volume 12, Issue 1, 103 – 115, 1997.
• Marques, S. Cruz, C. Antunes, F. Farias, J., “Step down converter with hysteretic current control for welding applications”, IECON 97. Volume: 2, 676 – 681.
• Morimoto, K., Doi, T., Manabe, H., Ahmed, N.A., Hyun Woo Lee, Mutsuo Nakaoka, Ahmed, T., Hiraki, E., “Dual utility AC voltage line operated soft switching PWM DCDC power converter with high frequency transformer link for arc welding equipment”, International Conference on Electrical Machines and Systems (ICEMS), 2005, Volume 2, 1084 – 1089.
• Morimoto, K., Doi, T., Manabe, H., Ahmed, N.A., Hyun- Woo Lee, Nakaoka, M., “Advanced high frequency transformer linked soft switching PWM DC-DC power converter with utility AC dual voltage modes for low voltage and large current applications”, European Conference on Power Electronics and Applications, 2005, 1-10.
• Morimoto, K., Doi, T., Manabe, H., Ahmed, N.A., Hyun- Woo Lee, Nakaoka, M., Ahmed, T., “An innovative DC busline active snubber-assisted soft switching PWM DCDC power supply with high frequency transformer for high performance arc welder”, Industry Applications Conference, 2005, Volume 3, 1965 – 1972.
• Uslu M., “Analysis, Design, and Implementation of a 5 kW zero voltage switching phase-shifted full-bridge DC/DC Converter based power supply for arc welding machines”, Yüksek Lisans Tezi, ODTÜ Fen Bilimleri Enstitüsü, Ankara, (2006).
• Dede, E.J., Jordan, J., Esteve, V., Cases, C., “New investigations on short-circuit behaviour of current-fed inverters for induction tube welding”, International Conference on Power Electronics and Drive Systems, 2001.Volume 2, 760 – 763.
• Vieira, P., Jr., Pinto, J.A.C., Bolhosa, D.M., Pereira, A.C., “Mathematical modeling and digital control for power supplies of current pulsed for welding machine”, European Conference on Power Electronics and Applications, 2005, 1-8.
• Lo, Y.-K., Wang, J.-M., "Current-regulated inverters with an output coupled inductor for AC arc welding machines," IET Power Electronics, vol.1, no.4, pp.445- 454, 2008.
• Mohan, N., Undeland, T.M., Robbins, W.P., “Power Electronics: Converters, Applications, and Design”, Wiley, 2002.
• Ayyanar, R., Giri, R., Mohan, N., “Active Input–Voltage and Load–Current Sharing in Input-Series and OutputParallel Connected Modular DC–DC Converters Using Dynamic Input-Voltage Reference Scheme” IEEE Tran. on Power Elec. vol. 19, no. 6, 1462-1473, 2004.
• Erickson, R.W., Maksimovic, D., “Fundamentals of Power Electronics”, Springer, 2001.
• McLyman, C.W.T., “Transformer and Inductor Design Handbook”, CRC Press, 2011.
• Cosmo Ferrites Product Catalog, http://www.cosmoferrites.com/
• Koparan A., “200 Amper, Yüksek Frekans Anahtarlamalı, DA ve AA/DA Kaynak Makinalarının Gelistirilmesi”, Yüksek Lisans Tezi, Gazi Üniversitesi Fen Bilimleri Enstitüsü, Ankara, 2010.
• Venable, H. Dean, “Practical Techniques for Analyzing, Measuring, and Stabilizing Feedback Control Loops in Switching Regulators and Converters”, Proceedings of the Seventh National Power Conversion Conference, 1983, I2-1 to I2-17.