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Three-phase power supply for resistance welding machine with corrected power factor

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Category: Electrical Complexes and Systems

Last Updated on 06 September 2017

Published on 06 September 2017

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Authors:

S.K.Podnebenna, Cand. Sc. (Tech.), Assoc. Prof., State Higher Educational Institution “Priazovskiy State Technical University”, Mariupol, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

V.V.Burlaka, Cand. Sc. (Tech.), Assoc. Prof., State Higher Educational Institution “Priazovskiy State Technical University”, Mariupol, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

S.V.Gulakov, Dr. Sc. (Tech.), Prof., State Higher Educational Institution “Priazovskiy State Technical University”, Mariupol, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Abstract:

Purpose. Development of a three-phase power supply for a single-phase resistance welding machine (RWM). The presented power supply utilizes active power factor correction and draws balanced grid currents. Usage of such power supplies allows ensuring electromagnetic compatibility of the RWM with the power grid.

Methodology. A mathematical model of the three-phase power supply for single phase RWM based on the frequency converter with direct coupling is developed. The model accounts for welding circuit parameters. Converter input and output currents, converter output voltage are shown. The following power quality parameters of the developed RWM power supply are calculated: power factor, harmonic distortion of input currents, negative sequence current ratio.

Findings. To ensure minimum power losses in the power grid, RWM power supply should present a symmetrical active load to the supply network. In case of symmetrical mains voltages, the consumed instantaneous active power is constant. On this basis, the RWM power supply converter operates in a rectifier mode providing constant power to the load. To avoid RWM transformer biasing and to prevent saturation of its magnetic core, the polarity of the converter output voltage is periodically changed. Thus, the primary voltage of the transformer has a form close to rectangular. Formation of the inverter output voltage with a predetermined amplitude and frequency is done by six bidirectional switches with pulse width modulation control. The developed control method allows controlling converter input currents to be proportional to the corresponding phase voltages.

Originality. The theoretical basis for the creation of new RWM power supplies with high energy efficiency and electromagnetic compatibility with the power grid is proposed.

Practical value. The use of the direct matrix type converter with developed control algorithm for RWM supply makes it possible to ensure the power supply electromagnetic compatibility with the power grid and to improve its energy efficiency by forming symmetrical input currents and eliminating reactive component of the input currents.

References.

1. Pismennyi, A.A., 2014. Improvement of power efficiency of machines for resistance spot welding by longitudinal compensation of reactive power. The Paton Welding Journal, 1, pp. 29–33.

2. Rudenko, P.M. and Gavrish, V.S., 2013. Thyristor Direct Converters for Supply of Resistance Welding Machines. The Paton Welding Journal, 8, pp. 55–58.

3. Rymar, S.V., Zhernosekov, A.M. and Sidorets, V.N., 2011. Effect of Single-Phase Power Sources of Welding Arc on Electric Mains. The Paton Welding Journal, 12, pp. 9–15.

4. Safronov, P.S., Bondarenko, Yu.V., Bondarenko, O.F., Sidorets, V.N. and Kucherenko, D.V., 2014. Increase in Electromagnetic Compatibility of Power Supplies for Resistance Welding. Tekhnichna Elektrodynamika, 5, pp. 89‒91.

5. Saleem, J., 2012. Power Electronics for Resistance Spot Welding Equipment. In: Mid Sweden University Licentiate Thesis. Sundsvall.

6. Podnebenna, S.K., Burlaka, V.V. and Gulakov, S.V., 2012. Reducing the level of distortions, generated by the welding power sources by the shunt active power filter with high efficiency. HERALD of the Donbass State Engineering Academy: Collection of science papers, 3, pp. 221–226.

04_2017_Podnebenna
2017-09-05  411.8 KB  850

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