Journal of Power Electronics

The Korean Institute of Power Electronics (전력전자학회)
권호 표지
DOI QR코드

DOI QR Code

Design of a welding power supply with wide input voltage range

  • Received : 2023.02.01
  • Accepted : 2023.04.10
  • Published : 2023.07.20
⟨ Previous Next ⟩

Abstract

This paper proposes a power supply for welding that can adapt to a wide range of input voltages. The phase-shifted full-bridge (PSFB) converter, which is widely used as a welding power supply, is not suitable for applications where there is a wide input voltage range because of an increase in the circulating current and high-voltage stresses on the switch devices when a high input voltage is applied. To address this issue, a method to change the structure based on the input voltage is proposed by dividing the primary-side high-frequency inverter stage of the PSFB converter into two and adding path switches that can be configured in series or in parallel. The proposed circuit can lower the switch devices withstand voltage through structural changes and operate in a duty ratio with narrow fluctuations on the wide input voltage, which helps to improve the overall efficiency. The validity of the proposed method was verified through a comparison with existing topologies on a 6.6 kW prototype.

Keywords

Acknowledgement

This work was supported by a Korea Agency for Infrastructure Technology Advancement (KAIA) grant funded by the Ministry of Land, Infrastructure and Transport (Grant 21HCLP-C162885-01) and the Vehicle Industry Technology Development Program funded By the Ministry of Trade, Industry & Energy (Grant 20018958)

References

  1. Castner, H. R. Chair: Welding Handbook Committee 1999-2001
  2. Erickson, R.W.: Fundamentals of power electronics, 2nd edn. Kluwer Academic Publishers, Secaucus (2000)
  3. Davidson, C.D.: Zero voltage switching full-bridge converter topology, vol. 2010, pp. 1-7. Intelec, Bristol (2010). https://doi.org/10.1109/INTLEC.2010.5525647
  4. Jensen, J.S.: Maritime welding handbook welding and related processes for repair and maintenance onboard 11th edition Revision. Wilhelmsen ships service (2009)
  5. Wintrich, A., Nicolai, U., Tursky, W., Reimann, T.: Application manual power semiconductors, 2nd edn. SEMIKRON, Nuremberg (2015)
  6. Song, X., Sha, D., Liao, X.: Input-series common transformer connected PS-FB DC-DC converters for pulsed MIG welding, 2012 Twenty-Seventh Annual IEEE Applied Power Electronics Conference and Exposition (APEC), 2012, pp. 2195-2199, doi: https://doi.org/10.1109/APEC.2012.6166126
  7. Losee et al.: SiC MOSFET design considerations for reliable high voltage operation, 2017 IEEE International Reliability Physics Symposium (IRPS), 2017, pp. 2A-2.1-2A-2.8 doi: https://doi.org/10.1109/IRPS.2017.7936254
  8. Sabate, J. A., Vlatkovic, V., Ridley, R. B., Lee, F. C., Cho, B. H.: Design considerations for high-voltage high-power full-bridge zero-voltage-switched PWM converter, Fifth Annual Proceedings on Applied Power Electronics Conference and Exposition, 1990, pp. 275-284, doi: https://doi.org/10.1109/APEC.1990.66420
  9. Redl, R., Sokal, N. O., L. Balogh, L.: A novel soft-switching full-bridge DC/DC converter: Analysis, design considerations, and experimental results at 1.5 kW, 100 kHz, 21st Annual IEEE Conference on Power Electronics Specialists, 1990, pp. 162-172, doi: https://doi.org/10.1109/PESC.1990.131185
  10. Neugebauer, T.C., Phinney, J.W., Perreault, D.J.: Filters and components with inductance cancellation. IEEE Trans Ind Appl 40(2), 483-491 (2004). https://doi.org/10.1109/TIA.2004.824487
  11. Chen, W., Lee, F. C., Jovanovic, M. M., Sabate, J. A.: A comparative study of a class of full bridge zero-voltage-switched PWM converters, Proceedings of 1995 IEEE Applied Power Electronics Conference and Exposition-APEC'95, 1995, pp. 893-899 vol.2, doi: https://doi.org/10.1109/APEC.1995.469046
  12. Kim, T. -H., Lee, S. -J., Choi, W.: Design and control of the phase shift full bridge converter for the on-board battery charger of the electric forklift, 8th International Conference on Power Electronics-ECCE Asia, 2011, pp. 2709-2716, doi: https://doi.org/10.1109/ICPE.2011.5944761
  13. Khan, M. S., Sathyan, S., Sugali, H., Chandra Bommagani, S. S.: Design of On-Board Battery Charger using Interleaved Bridgeless Type PFC and Phase Shifted Full Bridge Converter, 2020 IEEE International Students' Conference on Electrical, Electronics and Computer Science (SCEECS), 2020, pp. 1-5, doi: https://doi.org/10.1109/SCEECS48394.2020.65
  14. Duk-Hyeon, Y., Woo-Seok, L., Jun-Young, L., Il-Oun, L.: Phase-shifted full-bridge converter for welding-power supply capable of using 220V, 440V 3-phase grid voltages. Trans Korean Inst Power Electron (2021). https://doi.org/10.6113/TKPE.2021.26.5.372
  15. Seung-Won, C., Jun-Young, L.: A Study on Soft-Switching Circuit under Entire Load Condition and Passive Load Sharing Technique of Welding Power Supplies, Ph.D Thesis Myongji University Graduate School, 2021. Seoul, I804:11023-000000075993