The basic principle of inverter welding is to rectify the main input with a frequency of 50 Hz and AC110-220 volts to 110-220 volts DC and zero hertz. The rectified direct current voltage is then sent to the MOSFET. The MOSFET is a modern component with high switching, converting this 110-220V rectified DC voltage from 20KHz to 120-220AC volts with a frequency of 100KHz. This 110-220V AC output, with a frequency of 20KHz to 100KHz, is reduced to a 20-80V AC supply with the same frequency by a step-down transformer.
This procedure is the same for any inverter welding machine. Some inverter welders operate 20 to 80V AC with a frequency of 20KHz to 100 KHz as the final output. However, some inverter welding machines convert AC 20-80V into DC 20-80V as the final output for use.
Thus, the outline of the inverter welding machine is explained. Now, we will explain the operation of the inverter welding machine in simple words so that you can understand it well. Well, let’s get started.
Working of Inverter Welder Explanation
The following steps below will explain step by step how a modern inverter welder works.
Step 1: Input AC supply 110-220V AC &50Hz
First, a transformer is used as a power supply, as is the case with conventional transformer welders and other transformer welders. The input power supply is also the same as a transformer welding machine. Its supply range is mainly AC110V in Europe and the United States and AC220V in Asia. The input power supply range is AC110-240V.
Step 2: Rectification of input Supply to 110-220V Dc &Zero Hertz
Input 110-220 AC volts are rectified. The simple meaning of rectification is to convert AC (alternating current) with a frequency of 50 Hz to DC (direct current) 110-220V DC without a frequency. Simply put, rectification involves a procedure to reduce the frequency. The frequency is in the AC, and the DC has no frequency at all.
Alternating current changes the polarity 50 times per second, but direct current does not change the frequency, so the polarity does not change, and the frequency is zero. The rectification process is carried out by the use of rectifiers, also known as diodes.
A diode is an electrical component that allows the current to flow only in one direction. Since the resistance in the reverse direction is infinite, theoretically, the current flow in the reverse direction is zero. The bridge configuration converts AC to DC and reduces the AC frequency to zero.
The transformer can’t perform this task because it only converts the power by stepping down and boosting the voltage and current while keeping the frequency the same.
Step 3: Increasing the frequency of Rectified DC Volt from 0KHz to 20-100KHz
The rectified frequency of 110-240 V DC is 0 HZ. The inverter welding machine does not operate unless the frequency of the input power supply is raised. Therefore, to increase the frequency, we have built-in modern electronic circuits that perform this task.
This is done by MOSFETS (metal-oxide-semiconductor field-effect transistor), the latest electronic circuit to carry out this task. Typically, the number of MOSFETs is 4 to 16 for 5 to 10 amps. But the number increases with the range of input and output of the current. One inverter welding machine can reach 100 pieces.
MOSFETs obtain a rectified DC power supply and increase the frequency (the polarity period of the AC voltage). Each MOSFET performs this task in milliseconds to nanoseconds. The combined effect of all MOSFETs increases the frequency and increases the frequency from 20 khz to 100 khz.
The action of an increase in the frequency of the inverter welding machine is different, respectively. It depends on multiple factors. Its supply, output, and most importantly, the welding work that it must perform.
Some modern inverter welders use the latest MOSFET, the insulated gate bipolar transistor (IGPT), which performs this task to increase the frequency. These are very smart, so the work is very fast.
Step 4: Stepping Down of 110-220V AC to 20-80V AC supply keeping frequency 20khz-100khz
In the next step, the high-frequency signals of 20 to 100 khz AC 110 to 220 V are reduced to DC 20 to 80 V, which is the final welding output of some inverter welders operating at the reduced AC output.
This step is performed by using a step-down transformer that performs this task. The step-down transformer is very small compared to other transformers used in welding machines in the past. This is the basic reason why modern inverter welders are lighter and more efficient than old transformers.
Step5: Rectification of 20-80V AC & 20-100khz to 20-80DC and 0khz
This step is not in all inverters. Present only in inverter welders that use DC for final output.
This step is the same as the second step, for which a rectifier and a diode are required. As a result of this step and rectification by the diode, the AC of 20-80 V is converted into a DC of 20-80 V having a frequency of zero. In modern inverter welders that use direct current as the final output, this is the final output.
Step 6: DC AND AC output switcher
As mentioned above, some inverters operate at 20-80V AC output, and some inverter welders operate at 20-80V DC output. These two outputs are directly related to the performance of the arc generated in the case of both power supplies. The arc generated at the AC output is very fast, and it supports light metal and light penetration.
However, the DC output is good for heavy metals, stable arcs, and deep penetration into the metal. In order to make these two available in one inverter welding machine, the welding machine has a button to switch the output from AC to DC, and it supports a variety of metals.
Step 7: Regulation of ARC intensity
This is an additional step present in all modern inverter welders. The current value is increased or decreased, and the arc strength of the welding machine is increased or decreased. It is also useful when working between different metals. It also works at some points in the same metal.
Some advantages of using an Inverter welder
Inverter welders have the following good features, which make them unique and better as compared to others:
- Compact
- Lightweight due to small transformer
- Low power consumption
- High efficiency (70-80%)
- Stable and smooth arc
Limitations
- No heavy duty
- High cost
- Repair very tough
We have reported the latest work of inverter welding machine. I appreciate your understanding. If you have any questions, please ask them in the comments below. We will do our best to resolve your doubts.