Chapter 1
A little history
1.1. Invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2
Basics arc welding
2.1. Electric arc
Physical entity
Volt-ampere characteristics
Manual welding on direct current
Semi-automatic DC welding
AC Welding
2.2. Welding process
Non-consumable electrode welding
Consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3
Simulator LTspice IV
3.1. Simulation of power supply operation
Simulation capabilities
Electronic circuit simulation programs
Features of the LTspice IV program
3.2. Operation of the LTspice IV program
Starting the program
Drawing a circuit of a simple multivibrator on a PC
Defining numerical parameters and types of circuit components
Simulation of multivibrator operation
3.3. Simulation of a simple power supply
Low voltage source direct current
Test node
Chapter 4
AC Welding Power Sources
4.1. Features of terminology
4.2. Basic requirements for a welding source
4.3. Model electric arc alternating current
4.4. Welding source with ballast rheostat (active resistance)
4.5. Welding source with linear choke (inductive reactance)
4.6. welding transformer
4.7. How to calculate leakage inductance?
Leakage inductance of a transformer with cylindrical windings
Leakage inductance of a transformer with windings spaced apart
Leakage inductance of a transformer with disc windings
4.8. Requirements for a welding transformer
4.9. Classic AC power source
Calculation of a welding transformer with developed magnetic leakage
Design of AC Welding Power Source
4.10. Budyonny welding source
Ways to reduce the amount of current consumed
Structural electrical diagram of Budyonny's welding source
General principles for designing a welding source
Budyonny welding source model
Overcoming the design limitations of the Budenny welding source
Determining the overall power of a transformer
Core selection
Winding calculation
Magnetic Shunt Calculation
Leakage inductance calculation
Simulation of calculation results
Welding source design with alternative transformer design
4.11. Welding source with resonant capacitor
Calculation of a welding source with a resonant capacitor
Calculation of a welding transformer
Checking the placement of windings in the welding transformer window
Leakage inductance calculation
Welding source simulation
4.12. AC Arc Stabilizers
Features of AC welding arc
Operating principle of the arc stabilizer
First version of arc stabilizer
Details
Second version of the arc stabilizer
Details
Chapter 5
Welding source for semi-automatic welding
5.1. Basics of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation of the source power transformer
Model setup procedure
Calculation of ohmic resistance of windings
Calculation of inductance and resistance of transformer windings
Calculation overall dimensions transformer
Completing the transformer calculation
Calculation of the feed current source choke
5.3. Description of the design of a simple source for semi-automatic welding
Diagram of a simple source for semi-automatic welding
Parts for semi-automatic welding machine
Design and manufacture of welding transformer
Throttle design
Source connection
Chapter 6
Welding source for semi-automatic welding with thyristor regulator
6.1. Adjustment welding current
6.2. Ensuring continuity of welding current
6.3. Calculation of a welding transformer
6.4. Control block
6.5. Description of the design of a welding source with a thyristor regulator
Electrical circuit diagram
Details
Welding transformer design
Throttle design
Source connection
Chapter 7
Electronic welding current regulator
7.1. Multi-station welding
Multi-station welding with connection
through an individual ballast rheostat
Electronic analogue of the ballast rheostat ERST
7.2. Calculation of the main components of ERST
7.3. Description of ERST
Basic protection options
Purpose of the main components of ERST
Operating principle
Operating principle and configuration of block A1
Details
Operating principle and configuration of block A2
The principle of operation of the stabilizer
Details
Settings
Formation external characteristics ERST
Operating principle of the ERST control unit
Operating principle of the key transistor driver unit
Final ERST setup
Chapter 8
Inverter welding source
8.1. A little history
8.2. general description source
8.3. Recommendations for self-made ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of galvanic isolation transformer
8.11. PWM controller TDA4718A
8.12. Schematic diagram control unit for inverter welding source “RytmArc”
8.13. Formation of the load characteristic of the source
8.14. CU setting method
8.15. Remote control panel (modulator)
8.16. Using an alternative PWM controller
8.17. transformer driver
8.18. Damping chain that does not dissipate energy
Chapter 9
Inverter welding source COLT-1300
9.1. general description
What is this chapter about
Purpose
Main characteristics
9.2. Power part
Winder data
9.3. Control block
Functional diagram
Operating principle
Schematic diagram
Implementation of the Anty-Stick function
Implementation of the Arc Force function
9.4. Settings
Chapter 10
Helpful information
10.1. How to test unknown hardware?
10.2. How to calculate a transformer?
10.3. How to calculate a choke with a core?
Calculation features
Example of calculation of throttle No. 1
Example of calculation of throttle No. 2
Example of calculation of throttle No. 3
10.4. Calculation of chokes with powder core
Advantages of Powder Cores
Inductor Design Software address and installation
Automatic calculation functions of Inductor Design Software
Additional Features of Inductor Design Software
Inductor Design Software menu bar
Example of choke calculation in Inductor Design Software
Magnetics Inductor Design Using Powder Cores
Example of inductor calculation in Magnetics Inductor Design Using Powder Cores
10.5. How to calculate a radiator?
10.6. Hysteresis model of nonlinear inductance of the LTspice simulator
Brief description of the hysteresis model of nonlinear inductance
Selection of parameters of the hysteresis model of nonlinear inductance
10.7. Modeling complex electromagnetic components using LTspice
Modeling problem
The principle of similarity of electric and magnetic circuits
Duality of physical circuits
Model of an unbranched magnetic circuit
Simulation of a branched magnetic circuit
Simulation of a complex magnetic circuit
Adaptation of the model for magnetic circuits operating with partial or full magnetization
Creating an Integrated Magnetic Component Model
10.8. How to make welding electrodes?
Introduced more than a hundred years ago, electric arc welding created a technological revolution. To date, it has practically replaced all other metal welding technologies. The book provides the necessary information on manual and semi-automatic electric arc welding, as well as, in order of complexity, descriptions of various welding sources suitable for repetition.
The narration is accompanied necessary techniques calculations, diagrams and drawings. Much attention is paid to modeling using the popular SwCAD 111 program. Following the author's recommendations, readers will be able to independently calculate and manufacture sources for manual and semi-automatic welding, and those wishing to purchase a ready-made device can make right choice. The book is intended for a wide range of home craftsmen and radio amateurs interested in electric welding issues.
Chapter 1. A little history
1.1. Invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2: Arc Welding Basics
2.1. Electric arc
Physical entity
Volt-ampere characteristics
Manual DC welding
Semi-automatic DC welding
AC Welding
2.2. Welding process
Non-consumable electrode welding
Consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3. SwCAD III Simulator
3.1. Simulation of power supply operation
Simulation capabilities
Electronic circuit simulation programs
Features of the LTspice/SwitcherCAD III program
3.2. How SwCAD III works
Starting the program
Drawing a circuit of a simple multivibrator on a PC
Defining numerical parameters and types of circuit components
Simulation of multivibrator operation
3.3. Simulation of a simple power supply
Low Voltage DC Power Supply
Test node
Chapter 4. AC Welding Power Source
4.1. Manual welding with stick electrodes
Conditions for ensuring high quality welding
AC Electric Arc Model
Welding source with ballast rheostat (active resistance)
Welding source with linear choke (inductive reactance)
Welding source with choke and capacitor
4.2. welding transformer
Features of specialized welding transformers
How to calculate leakage inductance?
Requirements for a welding transformer
Calculation of a welding transformer
Specifying the transformer core window configuration
Design of AC Welding Power Source
Chapter 5. Welding source for semi-automatic welding
5.1. Basics of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation of the source power transformer
Model setup procedure
Calculation of ohmic resistance of windings
Calculation of inductance and resistance of transformer windings
Calculation of overall dimensions of the transformer
Completing the transformer calculation
Calculation of the feed current source choke
5.3. Description of the design of a simple source for semi-automatic welding
Diagram of a simple source for semi-automatic welding
Parts for semi-automatic welding machine
Design and manufacture of welding transformer
Throttle design
Source connection
Chapter 6. Welding source for semi-automatic welding with a thyristor regulator
6.1. Adjusting the welding current
6.2. Ensuring continuity of welding current
6.3. Calculation of a welding transformer
6.4. Control block
6.5. Description of the design of a welding source with a thyristor regulator
Electrical circuit diagram
Details
Welding transformer design
Throttle design
Source connection
Chapter 7. Electronic welding current controller
7.1. Multi-station welding
Multi-station welding with connection via an individual ballast rheostat
Electronic analogue of the ballast rheostat ERST
7.2. Calculation of the main components of ERST
7.3 Description of ERST
Basic protection options
Purpose of the main components of ERST
Operating principle
Operating principle and configuration of block A1
Operating principle and configuration of block A2
The principle of operation of the stabilizer
Settings
Formation of external characteristics of ERST
Operating principle of the ERST control unit
Operating principle of the key transistor driver unit
Final ERST setup
Chapter 8. Inverter Welding Source
8.1. Prehistory
8.2. General description of the source
8.3. Recommendations for self-production of ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of galvanic isolation transformer
8.11. PWM controller TDA4718A
Control unit (CU)
Voltage Controlled Oscillator (VCO)
Sawtooth voltage generator (SPG)
Phase comparator (PC)
Counting trigger
Comparator K2
Trigger Trigger
Short circuit comparator
Comparator K4
Soft start
Error Trigger
Comparators K5, K6, K8 and VRF overcurrent
Comparator K7
Exits
Reference voltage
8.12. Control unit for inverter welding source “RytmArc”
Schematic diagram
Control unit nodes
8.13. Formation of the load characteristic of the source
The main sections of the CVC
Means for the formation of the CVC
CU setting method
8.14. Using an alternative PWM controller
Replacing the outdated TDA4718A PWM controller
Features of the TDA4718A chip
8.15. transformer driver
Chapter 9. Useful information
9.1. How to test unknown hardware?
9.2. How to calculate a transformer?
9.3. How to calculate a choke with a core?
Calculation features
Calculation example No. 1
Calculation example No. 2
Calculation example No. 3
9.4. How to calculate a radiator?
9.5. How to make welding electrodes?
List of used literature and Internet resources
There are a lot of inexpensive semi-automatic welding machines on the market that will never work properly because they were made incorrectly from the start. Let's try to fix this on a welding machine that has already fallen into disrepair.
I got my hands on Chinese semi-automatic welding Vita (from now on I will simply call it PA), in which the power transformer burned out, friends just asked me to repair it.
They complained that when they were still working, it was impossible for them to cook anything, there were strong splashes, crackling, etc. So I decided to bring it to a conclusion, and at the same time share my experience, maybe it will be useful to someone. Upon first inspection, I realized that the transformer for the PA was wound incorrectly, since the primary and secondary windings were wound separately; the photo shows that only the secondary remained, and the primary was wound next to it (that’s how the transformer was brought to me).
This means that such a transformer has a steeply falling current-voltage characteristic (volt-ampere characteristic) and is suitable for arc welding, but not for PA. For Pa, you need a transformer with a rigid current-voltage characteristic, and for this, the secondary winding of the transformer must be wound on top of the primary winding.
In order to start rewinding the transformer, you need to carefully unwind the secondary winding without damaging the insulation, and cut off the partition separating the two windings.
For the primary winding I will use 2 mm thick enamel copper wire; for complete rewinding we will need 3.1 kg of copper wire, or 115 meters. We wind turn to turn from one side to the other and back. We need to wind 234 turns - that's 7 layers, after winding we make a tap.
We insulate the primary winding and taps with fabric tape. Next we wind the secondary winding with the same wire that we wound earlier. We wind tightly 36 turns, with a shank of 20 mm2, approximately 17 meters.
The transformer is ready, now let's work on the choke. The throttle is an equally important part in the PA, without which it will not work normally. It was made incorrectly because there is no gap between the two parts of the magnetic circuit. I will wind the choke on iron from the TS-270 transformer. We disassemble the transformer and take only the magnetic circuit from it. We wind a wire of the same cross-section as on the secondary winding of the transformer on one bend of the magnetic circuit, or on two, connecting the ends in series, as you like. The most important thing in the inductor is the non-magnetic gap, which should be between the two halves of the magnetic circuit; this is achieved by PCB inserts. The thickness of the gasket ranges from 1.5 to 2 mm, and is determined experimentally for each case separately.
Chapter 1. A little history
1.1. Invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2: Arc Welding Basics
2.1. Electric arc
Physical entity
Volt-ampere characteristics
Manual DC welding
Semi-automatic DC welding
AC Welding
2.2. Welding process
Non-consumable electrode welding
Consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3. SwCAD III Simulator
3.1. Simulation of power supply operation
Simulation capabilities
Electronic circuit simulation programs
Features of the LTspice/SwitcherCAD III program
3.2. How SwCAD III works
Starting the program
Drawing a circuit of a simple multivibrator on a PC
Defining numerical parameters and types of circuit components
Simulation of multivibrator operation
3.3. Simulation of a simple power supply
Low Voltage DC Power Supply
Test node
Chapter 4. AC Welding Power Source
4.1. Manual welding with stick electrodes
Conditions for ensuring high quality welding
AC Electric Arc Model
Welding source with ballast rheostat (active resistance)
Welding source with linear choke (inductive reactance)
Welding source with choke and capacitor
4.2. welding transformer
Features of specialized welding transformers
How to calculate leakage inductance?
Requirements for a welding transformer
Calculation of a welding transformer
Specifying the transformer core window configuration
Design of AC Welding Power Source
Chapter 5. Welding source for semi-automatic welding
5.1. Basics of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation of the source power transformer
Model setup procedure
Calculation of ohmic resistance of windings
Calculation of inductance and resistance of transformer windings
Calculation of overall dimensions of the transformer
Completing the transformer calculation
Calculation of the feed current source choke
5.3. Description of the design of a simple source for semi-automatic welding
Diagram of a simple source for semi-automatic welding
Parts for semi-automatic welding machine
Design and manufacture of welding transformer
Throttle design
Source connection
Chapter 6. Welding source for semi-automatic welding with a thyristor regulator
6.1. Adjusting the welding current
6.2. Ensuring continuity of welding current
6.3. Calculation of a welding transformer
6.4. Control block
6.5. Description of the design of a welding source with a thyristor regulator
Electrical circuit diagram
Details
Welding transformer design
Throttle design
Source connection
Chapter 7. Electronic welding current controller
7.1. Multi-station welding
Multi-station welding with connection via an individual ballast rheostat
Electronic analogue of the ballast rheostat ERST
7.2. Calculation of the main components of ERST
7.3. Description of ERST
Basic protection options.
Purpose of the main components of ERST
Operating principle
Operating principle and configuration of block A1
Operating principle and configuration of block A2
The principle of operation of the stabilizer
Settings
Formation of external characteristics of ERST
Operating principle of the ERST control unit
Operating principle of the key transistor driver unit
Final ERST setup
Chapter 8. Inverter Welding Source
8.1. Prehistory
8.2. General description of the source
8.3. Recommendations for self-production of ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of galvanic isolation transformer
8.11. PWM controller TDA4718A
Control unit (CU)
Voltage Controlled Oscillator (VCO)
Sawtooth voltage generator (SPG)
Phase comparator (PC)
Counting trigger
Comparator K2
Trigger Trigger
Comparator K3
Comparator K4
Soft start
Error trigger
Comparators K5, K6, K8 and VRF overcurrent
Comparator K7
Exits
Reference voltage
8.12. Control unit for inverter welding source “RytmArc”
Schematic diagram
Control unit nodes
8.13. Formation of the load characteristic of the source
The main sections of the CVC
Means for the formation of the CVC
8.14. CU setting method
8.15. Using an alternative PWM controller
Replacing the outdated TDA4718A PWM controller
Features of the TDA4718A chip
8.16. transformer driver
Chapter 9. Useful information
9.1. How to test unknown hardware?
9.2. How to calculate a transformer?
9.3. How to calculate a choke with a core?
Calculation features
Calculation example No. 1
Calculation example No. 2
Calculation example No. 3
9.4. How to calculate a radiator?
9.5. How to make welding electrodes?
List of used literature and Internet resources
