Medium frequency spot welding transformer and machine design

Presently, spot welding is an indispensable welding technique of modern industry. Unlike other metals, as aluminum is light, corrosion-resistant material, cheap material the usage of it in industry increases rapidly. However much power is required to spot welding of aluminum. Large machines on frequency are needed to meet this power with traditional welding methods. The use of inverter technolog in these machines eliminated the limit for operating frequency and the problem of size.In this study, mid-frequency spot weldıng machine design and electromagnetic analysis is performed. The design of the medium frequency spot welding machine was implemented using analytical and finite element methods.In mid-frequency applications is important to determine the conductive losses. In this study, unlike conventional welding machines winding type is determined as litz and foil. Each of the two winding losses are investigated. Litz conductor of the transformer primary winding is designed, selected as the secondary winding of the foil-type conductors.The designed transformer is delivered with sinusoidal PWM (SPWM) technique has been used with the inverter. The dynamic response of the transformer in various loads was investigated by controlling the inverter. Moreover, by examining these responses, electrode analysis was carried out in appropriate electrode and allows. Suitable electrod type and alloy were determined for spot welding.