Electronic Welding System
Our approach to this project is understood through the design and implementation of its input subsystem, output subsystem and control unit. In our project we need a spark in the end which cause the welding of two joints. In the beginning our input is 220 AC voltage at frequency of 50 Hz. It passes f
2025-06-28 16:32:22 - Adil Khan
Electronic Welding System
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryOur approach to this project is understood through the design and implementation of its input subsystem, output subsystem and control unit. In our project we need a spark in the end which cause the welding of two joints. In the beginning our input is 220 AC voltage at frequency of 50 Hz. It passes from rectifier and converted into DC voltage. After rectification capacitor is installed which remove the ripples of the DC voltage and converted into approximate pure DC voltage. After this voltage passes from H bridge inverter which convert this into again AC voltage but this voltage is at high frequency. The voltage is high that’s why we use step down transformer to decrease the voltage and increase the current.
As this is high frequency transformer its size is small as compare to our old trans- formers which is used in arc welding. This transformer is not iron core because iron core at high frequency or voltage the losses is increased and size also increased. Farad core transformer is used instead of iron core. After step down the voltage the current increases and voltage decreases then again rectifier from high frequency rectifier is used as normal rectifier did not work so it convert Ac into DC voltage. At output end the DC voltage is minimum which is not much effective for human health. But the current is too high when spark is produced. Current and voltage sensors also used to detect the current and voltage level if it increases from our range. Feedback system installed which control the inverter. Feedback system consist of a micro controller and its drivers which is used to control the opening and closing of gates of IGBTs which control our voltage.
- Design and development of Inverter for welding.
- Control of Inverter for welding.
- Human Protection.
In the beginning our input supply is a 220 AC voltage at a frequency of 50 Hz. This voltage is then pass through the rectifier and converted into DC voltage. This is pulsating DC which is than pass from low pass filter or simple capacitor bank and the ripples in DC are removed up to 90 percent. This DC voltage is pass to inverter which converter this into AC again and increases the frequency of this voltage. This voltage than pass from a step down transformer which low the voltage and increase the current. This is not a normal iron core transformer. We use ferrite core transformer to minimize the size and losses of the voltage. This voltage than pass to a high frequency rectifier which convert this into DC which is not too dangerous for human. When welding material in touch a spark is produced. The current is too high at the output end when the circuit is completed.A feed back system is used to control the voltage at the receiving end. A controller is used which control the opening and closing of IGBTs in inverter which control the voltage. Current and Voltage sensors are used to make this machine human friendly.
Benefits of the ProjectArc welding is the way of welding that utilizes an electrical arc to join solid materials. To take care of the issue of weight, size of arc welding machine and to make it human cordial, it is important to plan an inverter. The inverter gives a lot higher frequency than 50Hz or 60Hz which at that point supply to high frequency transformer. The welding noise produce by arc welding machine is diminished by picking the working frequency over the knowing about human capacity. The output welding current is constrained by controlling the IGBTs utilized in inverter at high frequency. Power switch IGBTs (Insulated Gate Bipolar Transistor) is utilized for the inverter configuration because of its high switching capacity.
Technical Details of Final DeliverableAs the hardware and programming industry developed, designs before long understood that product controlled inverter could be utilized for patching. This opened another universe of conceivable outcomes. Inverter development issues happened round the 1990’s and numerous early inverter welding machines were tormented with dependability issues. In the mid 2000’s, inverter welding machines were get- ting famous because of their adaptability and capacity to control the bend.
The primary inverter machines experienced the typical designing developing tor- ments, which comprised of profoundly disputable subjects about UI, control, heat dissemination, moistness issues, and numerous different issues. These issues stay at the focal point of the bantered about speculator selection. Taking into account that we are looking at welding machines, we might need to get to the core of weld- ing and talk about the bend and the welds that happen. On the off chance that I were the sort of welder who just welds mellow steel throughout the day. Consistently, I wouldn’t have to crackpot past a transformer machine. Not with standing, we live in a universe of welding that requests welding flawlessness in any position and on any material.
Enterprises incline toward inverter welding machine as it is more productive and versatile. Its minimal plan gives a spotless and amazing weld. At the point when you presently don’t need to utilize the organization truck to move your hardware to the field. This new innovation handles the voltage guideline of the machine and permits it to work with an old feeble generator which has conflicting force yield. Standard binding irons can be harmed during a force variance, yet an inverter utilizes its product to make up for any voltage changes. Since inverters have a high open circuit voltage than standard machines, inverters are simpler to begin and keep a bend. Because of every one of these advantages and properties,businesses favour this machine.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 40000 | |||
| Ac Supply | Equipment | 1 | 800 | 800 |
| Simple Rectifier | Equipment | 1 | 400 | 400 |
| LC Filter | Equipment | 1 | 700 | 700 |
| Inverter | Equipment | 1 | 2000 | 2000 |
| Ferrite Core Transformer | Equipment | 1 | 3000 | 3000 |
| Voltage sensor | Equipment | 1 | 800 | 800 |
| Current Sensor | Equipment | 1 | 1000 | 1000 |
| Temperature Sensor | Equipment | 1 | 700 | 700 |
| Welding Spark Apparatus | Equipment | 1 | 2000 | 2000 |
| Signal Condition | Equipment | 3 | 2000 | 6000 |
| Driver | Equipment | 2 | 3000 | 6000 |
| Micro Controller | Equipment | 1 | 2000 | 2000 |
| Iron Core Transformer | Equipment | 1 | 800 | 800 |
| Regulators | Equipment | 2 | 650 | 1300 |
| High Frequency Rectifier | Equipment | 1 | 2000 | 2000 |
| PCB Design | Miscellaneous | 1 | 2500 | 2500 |
| Wires and Connections | Miscellaneous | 1 | 2000 | 2000 |
| Photocopy Diagram | Miscellaneous | 1 | 500 | 500 |
| Resistors | Equipment | 1 | 1000 | 1000 |
| Trolley for Safety | Miscellaneous | 1 | 4000 | 4000 |
| Jumper Wires | Miscellaneous | 1 | 500 | 500 |