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Field-circuit modelling of the resistance spot welding transformers

Sakhno L., Sakhno O., Likhachev D, Fedorov P.

Przegląd Elektrotechniczny

2017

R. 93, nr 8

142--145

Transformers of high frequency resistance spot welding systems are considered. The equivalent circuit of a three-winding transformer, which is obtained by replacing it with two two-winding transformers, is used. It is shown that the magnetic coupling factor for the leakage fluxes of these two-winding transformers influences on the output current. The study of the transformers includes both 2D eddy-current FEA analysis for estimation the leakage impedance and the circuit simulation, which gives the output current. The results are used to design economical welding transformers. The calculation results are confirmed experimentally.

Zaprojektowano transformator do wsokoczestotliwościowego punktowego zgrzewania. Przeprowadzono analizę rozkładu prądów wiroychw celu uwzględnienia impedancji upływowej oraz zaproponowano schemat zastępczy transformatora trzy-uzwojeniowego otrzymanego przez zastąpienie dwóch transformatorów dwu-uzwojeniowych.

Field-circuit modelling of an advanced welding transformer with two parallel rectifiers

Sakhno L., Sakhno O., Dubitsky S.

Archives of Electrical Engineering

2015

Vol. 64, nr 2

249--257

The new topology of three-winding welding transformer is proposed. Each secondary winding is connected in parallel through the separate bridge rectifier to the welding arc. The main feature of the proposed device is parallel working of two secondary windings with different rated voltage. The advantage is nonlinear transformation ratio of current that provides unprecedented power efficiency. The self- and mutual leakage inductances, which are important in power conversion, are calculated by 2D FEA model. The operational current of the device is modelled numerically via P-Spice simulator. The proposed topology is up to 30% more power effective than conventional welding transformer provided that the leakage inductances of primary and secondary windings are correctly fitted. This transformer is used for manual arc welding.