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<p>The welding industry needs compatible and highly energy-efficient power sources so that they can be easily installed at the welding spots and used very effectively. In this paper, a Three-phase Isolated High Current DC-DC Converter (3ϕ-IHCC) using SiC devices, along with a phase Power Factor Correction (PFC) rectifier is proposed as a Welding Power Source Converter (WPSC) for industrial welding applications. High-frequency operation guarantees the reduced size and weight of reactive elements. Circulating currents and quality of input power supply are the parameters to design the proposed WPSC. A natural Zero Voltage Switching (ZVS) can be achieved by providing dead time between the same leg switches of 3ϕ-IHCC. A dual-loop controller has been applied for WPSC to limit the welding current and analyze the steady state and transient behavior of the converter has been analyzed. Constant Voltage (CV) and Rising characteristics have been studied by varying the arc length/welding current of WPSC. A prototype is fabricated for WPSC rated at 200 A, 6&#xa0;kW, and tested with Metal Inert Gas (MIG) based arc welding. The experimental results confirm the usefulness of the proposed converter for various arc welding processes.</p>

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Design, analysis and testing of three-phase isolated SiC-based high current DC-DC converter for arc welding power supply

  • 期刊论文

  • 发表日期：

    2025年4月19日

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  • Anil Marneni,
  • N. Babu,
  • Senthil Kumar Subramaniam,
  • Pravin Murugesan,
  • J. Jude Prakash

摘要

The welding industry needs compatible and highly energy-efficient power sources so that they can be easily installed at the welding spots and used very effectively. In this paper, a Three-phase Isolated High Current DC-DC Converter (3ϕ-IHCC) using SiC devices, along with a phase Power Factor Correction (PFC) rectifier is proposed as a Welding Power Source Converter (WPSC) for industrial welding applications. High-frequency operation guarantees the reduced size and weight of reactive elements. Circulating currents and quality of input power supply are the parameters to design the proposed WPSC. A natural Zero Voltage Switching (ZVS) can be achieved by providing dead time between the same leg switches of 3ϕ-IHCC. A dual-loop controller has been applied for WPSC to limit the welding current and analyze the steady state and transient behavior of the converter has been analyzed. Constant Voltage (CV) and Rising characteristics have been studied by varying the arc length/welding current of WPSC. A prototype is fabricated for WPSC rated at 200 A, 6 kW, and tested with Metal Inert Gas (MIG) based arc welding. The experimental results confirm the usefulness of the proposed converter for various arc welding processes.