Implementation of 200 ampere, high frequency switching DC and AC/DC arc welding machines

Inverter type welding machines are preferred by users due to their fast response, low volume and weight, and high efficiency values, and therefore their use has been steadily increasing. In these machines, rectified line voltage is switched at high frequency and transferred to the secondary of a high frequency transformer. Secondary voltage is rectified again and applied between the welding electrode and the piece to be welded. Welding current is adjusted by the duty cycle of the semiconductor switches in the primary circuit.In this thesis, simulation, power and control circuit design, and experimental work for a 5.6 kW inverter type welding machine are presented. The work has been conducted in cooperation with Nuris Electrical Machines and Welding Machines Company in the framework of a project supported by the Ministry of Industry.Sytem designed first as a DC welding machine and made simulations, The half bridge DC/DC circuit is added and AC welding machine simulations is completed.A dual-forward topology was used in the system. First, small signal analysis was carried out to check the stability of the system and to design the controller. Then, the controller was modeled and tested in Pspice and Simulink programs. Finally, experimental results are taken on the practical system developed by the project partner. Results are in good agreement.