Contribution of the two rectifiers reconfiguration to fault tolerance connected to the grid network to feed the GMAW through processor-in-the-loop

This study aims to propose a new diagnosis technique based on the Park’s vector and the polar coordinates of electric currents for the detection and location of open-circuit faults (OC) at the level of two rectifiers connected to the grid network to feed the Gas Metal Arc Welding process (GMAW). This diagnosis technique allows the early location of faulty switches (Thyristors) to overcome the negative effect of faulty rectifiers on welding current, welding voltage, and droplet diameter. For that, the reconfigurable rectifiers have been integrated to accomplish the welding process. The proposed diagnosis technique is applied to reconfigurable rectifiers connected to the GMAW system through numerical simulations using MATLAB/Simulink and real-time processor-in-the-loop (PIL) implementation via DSpace ds 1103 card. The simulation and PIL experimental results show similar trends and great success of the diagnosis technique and the two rectifiers reconfiguration for overcoming the open circuit faults and obtaining high welding quality while maintaining the work-piece and avoiding the distortions caused by the faulty rectifiers, which affecting the grid network and on the GMAW system at the same time.