To the question of construction of welding inverter sources with a high power factor

Abstract

Purpose. Design a power-factor-corrected, energy- and cost-efficient switchmode power supply for welding. Methodology. It is proposed to use the principle of direct conversion and to develop the "hybrid" power circuit consisting of a main power path using direct conversion and an auxiliary power path having a converter with an intermediate DC link with relatively low stored energy. Since a load to the welding power supply is the welding arc, its instantaneous power fluctuations during the mains voltage period essentially do not influence the welding process due to the thermal constant of the weld pool molten metal. Effective use of this features of the welding arc allows to optimize the power processing, reduce the amount of energy stored in the reactive elements of the circuit and improve the economical, mass and dimensional parameters of the supplies. Findings. A new power factor corrected switchmode power supply topology is proposed utilizing beforementioned principles of power processing. The algorithm for calculating the switching frequency of supply power switches is given. To confirm the adequacy of the developed provisions, an experimental sample of the power supply was created. Oscillograms of mains voltage and source current consumption and oscillograms in output current limitation mode are obtained. The results of experiments showed that the supply has a power factor > 0.94 in a wide range of powers. Originality. A distinctive feature of the supply is the absence of additional inductive components in the power path, a lower capacitance of the DC-link bulk capacitor and a simplified scheme for limiting its inrush current during initial charging. The supply has an increased open circuit voltage, independent of the mains voltage, which allows for easy arc ignition during manual arc welding. Practical value. Due to the increased power factor, the current drawn from the mains is 30 % to 45 % lower than that of widespread inverter supplies without a power factor corrector. These features allow to simultaneously use more power supply units with the same mains current load, and/or to provide stable welding in conditions of a "weak" mains.