Novel and simplified implementation of digital high-power pulsed MIG welding power supply with LLC resonant converter

IF 0.8 4区工程技术 Q4 ENGINEERING, ELECTRICAL & ELECTRONIC

Circuit World Pub Date : 2022-09-29 DOI:10.1108/cw-03-2022-0068

Kaiyuan Wu, Hao Huang, Ziwei Chen, M. Zeng, Tong Yin

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引用次数: 0

Abstract

Purpose This paper aims to overcome the limitations of low efficiency, low power density and strong electromagnetic interference (EMI) of the existing pulsed melt inert gas (MIG) welding power supply. So a novel and simplified implementation of digital high-power pulsed MIG welding power supply with LLC resonant converter is proposed in this work. Design/methodology/approach A simple parallel full-bridge LLC resonant converter structure is used to design the digital power supply with high welding current, low arc voltage, high open-circuit voltage and a wide range of arc loads, by effectively exploiting the variable load and high-power applications of LLC resonant converter. Findings The efficiency of each converter can reach up to 92.3%, under the rated operating condition. Notably, with proposed scheme, a short-circuit current mutation of 300 A can stabilize at 60 A within 8 ms. Furthermore, the pulsed MIG welding test shows that a stable welding process with 280 A peak current can be realized and a well-formed weld bead can be obtained, thereby verifying the feasibility of LLC resonant converter for pulsed MIG welding power supply. Originality/value The high efficiency, high power density and weak EMI of LLC resonant converter are conducive to the further optimization of pulsed MIG welding power supply. Consequently, a high performance welding power supply is implemented by taking adequate advantages of LLC resonant converter, which can provide equipment support for exploring better pulsed MIG welding processes.

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基于LLC谐振变换器的数字大功率脉冲MIG焊接电源的新颖简化实现

目的克服现有脉冲熔体惰性气体(MIG)焊接电源效率低、功率密度低、电磁干扰(EMI)强等缺点。为此，本文提出了一种基于LLC谐振变换器的数字大功率脉冲MIG焊接电源的简化实现方法。设计/方法/方法采用一种简单的并联全桥LLC谐振变换器结构，有效地利用LLC谐振变换器的可变负载和大功率应用，设计了具有高焊接电流、低电弧电压、高开路电压和大电弧负载范围的数字电源。结果:在额定工况下，各变流器的效率可达92.3%。值得注意的是，采用该方案，300 a的短路电流突变可以在8 ms内稳定在60 a。通过脉冲MIG焊接试验，实现了峰值电流为280 a的稳定焊接过程，并获得了成形良好的焊缝，从而验证了LLC谐振变换器用于脉冲MIG焊接电源的可行性。LLC谐振变换器的高效率、高功率密度和弱电磁干扰有利于脉冲MIG焊接电源的进一步优化。因此，充分利用LLC谐振变换器的优点，实现了高性能的焊接电源，为探索更好的脉冲MIG焊接工艺提供了设备支持。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Circuit World 工程技术-材料科学：综合

CiteScore

2.60

自引率

0.00%

发文量

审稿时长

>12 weeks

期刊介绍： Circuit World is a platform for state of the art, technical papers and editorials in the areas of electronics circuit, component, assembly, and product design, manufacture, test, and use, including quality, reliability and safety. The journal comprises the multidisciplinary study of the various theories, methodologies, technologies, processes and applications relating to todays and future electronics. Circuit World provides a comprehensive and authoritative information source for research, application and current awareness purposes. Circuit World covers a broad range of topics, including: • Circuit theory, design methodology, analysis and simulation • Digital, analog, microwave and optoelectronic integrated circuits • Semiconductors, passives, connectors and sensors • Electronic packaging of components, assemblies and products • PCB design technologies and processes (controlled impedance, high-speed PCBs, laminates and lamination, laser processes and drilling, moulded interconnect devices, multilayer boards, optical PCBs, single- and double-sided boards, soldering and solderable finishes) • Design for X (including manufacturability, quality, reliability, maintainability, sustainment, safety, reuse, disposal) • Internet of Things (IoT).