Bringing to mind the budget semi-automatic. We bring to mind a budget semiautomatic device We create modern welding machines Volodin
There are a lot of inexpensive semi-automatic welding machines on the market that will never work properly, because they were not made initially correctly. Let's try to fix this on a welding machine that has already become unusable.
I fell into the hands of a Chinese Vita semi-automatic welding machine (hereinafter I will simply call it PA), in which a power transformer burned out, my friends just asked me to repair it.
They complained that when they were still working, it was impossible for them to cook something, strong splashes, crackling, etc. So I decided to bring him to the senses, and at the same time share my experience, maybe someone will come in handy. At the first inspection, I realized that the transformer for the PA was not wound correctly, since the primary and secondary windings were wound separately, the photo shows that only the secondary remained, and the primary was wound nearby (this is how the transformer was brought to me).
And this means that such a transformer has a steeply falling CVC (voltage characteristic) and is suitable for arc welding but not for PA. For Pa, a transformer with a rigid IV characteristic is needed, and for this, the secondary winding of the transformer must be wound over the primary winding.
In order to start rewinding the transformer, you need to carefully unwind the secondary winding without damaging the insulation, and cut off the partition separating the two windings.
For the primary winding, I will use copper enamel wire 2 mm thick, 3.1 kg is enough for a full rewind copper wire, or 115 meters. We wind a coil to a coil from one side to the other and back. We need to wind 234 turns - this is 7 layers, after winding we make a tap.
We isolate the primary winding and taps with cloth tape. Then we wind the secondary winding with the wire that we unwound earlier. We wind tightly 36 turns, with a shank of 20 mm2, approximately 17 meters.
The transformer is ready, now let's deal with the throttle. The throttle is an equally important part in the PA without which it will not work properly. It was made incorrectly, because it does not have a gap between the two parts of the magnetic circuit. I will wind the inductor on iron from the TS-270 transformer. We disassemble the transformer and take only the magnetic circuit from it. Wire of the same section as on secondary winding we wind the transformer on one roll of the magnetic circuit, or on two by connecting the ends in series, as you like. The most important thing in the throttle is a non-magnetic gap, which should be between the two halves of the magnetic circuit, this is achieved by textolite inserts. The thickness of the gasket ranges from 1.5 to 2 mm, and is determined experimentally for each case separately.
Chapter 1
A bit of history
1.1. The invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2
Arc Welding Basics
2.1. Electric arc
physical entity
Volt-ampere characteristics
Manual DC welding
Semi-automatic DC welding
AC welding
2.2. Welding process
TIG welding
consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3
Simulator LTspice IV
3.1. Simulation of the power supply
Simulation Capabilities
Simulation programs electronic circuits
Features of LTspice IV
3.2. Operation of the LTspice IV program
Program launch
We draw a simple multivibrator circuit on a PC
Defining Numerical Parameters and Types of Schematic Components
Simulation of the operation of a multivibrator
3.3. Simulation of the simplest power supply
Low voltage source direct current
Test node
Chapter 4
Welding sources of alternating current
4.1. Features of terminology
4.2. Basic requirements for a welding source
4.3. AC arc model
4.4. Welding source with ballast rheostat (resistance)
4.5. Welding source with linear choke (inductive reactance)
4.6. welding transformer
4.7. How to calculate leakage inductance?
Leakage inductance of a transformer with cylindrical windings
Leakage inductance of a transformer with spaced windings
Leakage inductance of a disc-wound transformer
4.8. Requirements for a welding transformer
4.9. Classic AC source
Calculation welding transformer with developed magnetic scattering
Construction of AC welding source
4.10. Welding source Budyonny
Ways to reduce the amount of current consumed
Structural and electrical diagram of the welding source Budyonny
General principles for designing a welding source
Model of welding source Budyonny
Overcoming the design limitations of Budyonny's welding source
Determination of the overall power of the transformer
Core selection
Winding calculation
Magnetic Shunt Calculation
Leakage inductance calculation
Simulation of calculation results
Welding source design with alternative transformer design
4.11. Welding source with resonant capacitor
Calculation of a welding source with a resonant capacitor
Calculation of the welding transformer
Checking the placement of the windings in the window of the welding transformer
Leakage inductance calculation
Simulation of the welding source
4.12. AC arc stabilizers
Features of the AC welding arc
The principle of operation of the arc stabilizer
The first version of the arc stabilizer
Details
The second version of the arc stabilizer
Details
Chapter 5
Welding source for semi-automatic welding
5.1. Fundamentals of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation power transformer source
Model Tuning Procedure
Calculation of the ohmic resistance of the windings
Calculation of the inductance and resistance of the transformer windings
Calculation of the overall dimensions of the transformer
Completing the transformer calculation
Calculation of the inductor of the make-up current source
5.3. Description of the design of a simple source for semi-automatic welding
Scheme of a simple source for semi-automatic welding
Parts for semi-automatic welding
Design and manufacture of welding transformer
Choke design
Source connection
Chapter 6
Welding source for semi-automatic welding with thyristor regulator
6.1. Welding current adjustment
6.2. Ensuring the continuity of the welding current
6.3. Calculation of the welding transformer
6.4. Control block
6.5. Description of the design of the welding source with a thyristor regulator
Circuit diagram
Details
The design of the welding transformer
Choke design
Source connection
Chapter 7
Electronic welding current controller
7.1. Multi-station welding
Multi-station welding with connection
through an individual ballast rheostat
Electronic analogue of the ERST ballast rheostat
7.2. Calculation of the main units of ERST
7.3. Description of ERST
Basic protection options
Purpose of the main units of ERST
Operating principle
The principle of operation and setting of block A1
Details
The principle of operation and setting of block A2
The principle of operation of the stabilizer
Details
Setting
Formation of external characteristics of ERST
The principle of operation of the control unit ERST
The principle of operation of the key transistor driver unit
Final ERST setup
Chapter 8
Inverter welding source
8.1. A bit of history
8.2. general description source
8.3. Recommendations for self-manufacturing of ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of the galvanic isolation transformer
8.11. PWM controller TDA4718A
8.12. circuit diagram control unit of the inverter welding source "RytmArc"
8.13. Formation of the load characteristic of the source
8.14. CU setting method
8.15. Remote control control (modulator)
8.16. Using an alternative PWM controller
8.17. transformer driver
8.18. Damping circuit that does not dissipate energy
Chapter 9
Inverter welding source COLT-1300
9.1. general description
What is this chapter about
Purpose
Main characteristics
9.2. Power part
Winder data
9.3. Control block
Functional diagram
Operating principle
circuit diagram
Implementation of the Anty-Stick function
Implementation of the Arc Force function
9.4. Setting
Chapter 10
Helpful information
10.1. How to test unknown iron?
10.2. How to calculate a transformer?
10.3. How to calculate a core choke?
Calculation features
Choke Calculation Example #1
Choke calculation example No. 2
Throttle calculation example No. 3
10.4. Calculation of chokes with a powder core
Advantages of Powder Cores
Address of the Inductor Design Software and its installation
Automatic calculation functions of the Inductor Design Software
Additional features of the Inductor Design Software
Inductor Design Software Menu Bar
An example of a choke calculation in the Inductor Design Software
Magnetics Inductor Design Using Powder Cores
Inductor calculation example in Magnetics Inductor Design Using Powder Cores
10.5. How to calculate the radiator?
10.6. Hysteresis model of the nonlinear inductance of the LTspice simulator
Brief description of the hysteresis model of non-linear inductance
Selection of parameters for the hysteresis model of nonlinear inductance
10.7. Modeling Complex Electromagnetic Components with LTspice
Modeling problem
The principle of similarity of electric and magnetic circuits
Duality of physical circuits
Model of an unbranched magnetic circuit
Simulation of a branched magnetic circuit
Modeling a complex magnetic circuit
Adaptation of the model for magnetic circuits operating with partial or full bias
Creating a model of an integrated magnetic component
10.8. How to make welding electrodes?
Chapter 1
1.1. The invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2 Arc Welding Basics
2.1. Electric arc
physical entity
Volt-ampere characteristics
Manual DC welding
Semi-automatic DC welding
AC welding
2.2. Welding process
TIG welding
consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3 SwCAD III Simulator
3.1. Simulation of the power supply
Simulation Capabilities
Programs for modeling electronic circuits
Features of LTspice/SwitcherCAD III
3.2. Work of the SwCAD III program
Program launch
We draw a simple multivibrator circuit on a PC
Defining Numerical Parameters and Types of Schematic Components
Simulation of the operation of a multivibrator
3.3. Simulation of the simplest power supply
Low voltage DC power supply
Test node
Chapter 4 AC Welding Source
4.1. MMA welding
Conditions for ensuring High Quality welding
AC arc model
Welding source with ballast rheostat (resistance)
Welding source with linear choke (inductive reactance)
Welding source with choke and capacitor
4.2. welding transformer
Features of specialized welding transformers
How to calculate leakage inductance?
Requirements for a welding transformer
Calculation of the welding transformer
Transformer Core Window Configuration Refinement
Construction of AC welding source
Chapter 5. Welding source for semi-automatic welding
5.1. Fundamentals of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation of the power transformer of the source
Model Tuning Procedure
Calculation of the ohmic resistance of the windings
Calculation of the inductance and resistance of the transformer windings
Calculation of the overall dimensions of the transformer
Completing the transformer calculation
Calculation of the inductor of the make-up current source
5.3. Description of the design of a simple source for semi-automatic welding
Scheme of a simple source for semi-automatic welding
Parts for semi-automatic welding
Design and manufacture of welding transformer
Choke design
Source connection
Chapter 6. Welding source for semi-automatic welding with a thyristor regulator
6.1. Welding current adjustment
6.2. Ensuring the continuity of the welding current
6.3. Calculation of the welding transformer
6.4. Control block
6.5. Description of the design of the welding source with a thyristor regulator
Circuit diagram
Details
The design of the welding transformer
Choke design
Source connection
Chapter 7. Electronic Welding Current Controller
7.1. Multi-station welding
Multi-station welding with connection through an individual ballast rheostat
Electronic analogue of the ERST ballast rheostat
7.2. Calculation of the main units of ERST
7.3. Description of ERST
Basic protection options.
Purpose of the main units of ERST
Operating principle
The principle of operation and setting of block A1
The principle of operation and setting of block A2
The principle of operation of the stabilizer
Setting
Formation of external characteristics of ERST
The principle of operation of the control unit ERST
The principle of operation of the key transistor driver unit
Final ERST setup
Chapter 8. Inverter Welding Source
8.1. Prehistory
8.2. General description of the source
8.3. Recommendations for self-manufacturing of ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of the galvanic isolation transformer
8.11. PWM controller TDA4718A
Control unit (BU)
Voltage Controlled Generator (VCO)
Sawtooth voltage generator (SPG)
Phase comparator (FC)
Count trigger
Comparator K2
Shutdown trigger
Comparator K3
Comparator K4
Soft start
Error trigger
Comparators K5, K6, K8 and VRF overcurrent
Comparator K7
exits
Reference voltage
8.12. Control unit for inverter welding source "RytmArc"
circuit diagram
Control unit nodes
8.13. Formation of the load characteristic of the source
The main sections of the CVC
Means for the formation of the CVC
8.14. CU setting method
8.15. Using an alternative PWM controller
Replacements for the outdated TDA4718A PWM controller
Features of the TDA4718A chip
8.16. transformer driver
Chapter 9
9.1. How to test unknown iron?
9.2. How to calculate a transformer?
9.3. How to calculate a core choke?
Calculation features
Calculation example No. 1
Calculation example No. 2
Calculation example No. 3
9.4. How to calculate the radiator?
9.5. How to make welding electrodes?
List of used literature and Internet resources
Appearing more than a hundred years ago, electric arc welding made a technological revolution. To date, it has practically supplanted all other metal welding technologies. The book provides the necessary information on manual and semi-automatic arc welding, as well as, in order of complication, descriptions of various welding sources suitable for repetition.
The narrative is accompanied by the necessary calculation methods, diagrams and drawings. Much attention is paid to modeling using the popular SwCAD 111 program. Following the author's recommendations, readers will be able to independently calculate and manufacture sources for manual and semi-automatic welding, and those who wish to purchase finished device- do right choice. The book is intended for a wide range of home craftsmen, radio amateurs interested in electric welding.
Chapter 1
1.1. The invention of electric welding
1.2. Development of electric welding in the 20th century
Chapter 2 Arc Welding Basics
2.1. Electric arc
physical entity
Volt-ampere characteristics
Manual DC welding
Semi-automatic DC welding
AC welding
2.2. Welding process
TIG welding
consumable electrode welding
Metal transfer
2.3. Main characteristics of welding arc power sources
Chapter 3 SwCAD III Simulator
3.1. Simulation of the power supply
Simulation Capabilities
Programs for modeling electronic circuits
Features of LTspice/SwitcherCAD III
3.2. Work of the SwCAD III program
Program launch
We draw a simple multivibrator circuit on a PC
Defining Numerical Parameters and Types of Schematic Components
Simulation of the operation of a multivibrator
3.3. Simulation of the simplest power supply
Low voltage DC power supply
Test node
Chapter 4 AC Welding Source
4.1. MMA welding
Conditions for high quality welding
AC arc model
Welding source with ballast rheostat (resistance)
Welding source with linear choke (inductive reactance)
Welding source with choke and capacitor
4.2. welding transformer
Features of specialized welding transformers
How to calculate leakage inductance?
Requirements for a welding transformer
Calculation of the welding transformer
Transformer Core Window Configuration Refinement
Construction of AC welding source
Chapter 5. Welding source for semi-automatic welding
5.1. Fundamentals of semi-automatic welding
5.2. Calculations of circuit elements
Determination of parameters and calculation of the power transformer of the source
Model Tuning Procedure
Calculation of the ohmic resistance of the windings
Calculation of the inductance and resistance of the transformer windings
Calculation of the overall dimensions of the transformer
Completing the transformer calculation
Calculation of the inductor of the make-up current source
5.3. Description of the design of a simple source for semi-automatic welding
Scheme of a simple source for semi-automatic welding
Parts for semi-automatic welding
Design and manufacture of welding transformer
Choke design
Source connection
Chapter 6. Welding source for semi-automatic welding with a thyristor regulator
6.1. Welding current adjustment
6.2. Ensuring the continuity of the welding current
6.3. Calculation of the welding transformer
6.4. Control block
6.5. Description of the design of the welding source with a thyristor regulator
Circuit diagram
Details
The design of the welding transformer
Choke design
Source connection
Chapter 7. Electronic Welding Current Controller
7.1. Multi-station welding
Multi-station welding with connection through an individual ballast rheostat
Electronic analogue of the ERST ballast rheostat
7.2. Calculation of the main units of ERST
7.3 Description of ERST
Basic protection options
Purpose of the main units of ERST
Operating principle
The principle of operation and setting of block A1
The principle of operation and setting of block A2
The principle of operation of the stabilizer
Setting
Formation of external characteristics of ERST
The principle of operation of the control unit ERST
The principle of operation of the key transistor driver unit
Final ERST setup
Chapter 8. Inverter Welding Source
8.1. Prehistory
8.2. General description of the source
8.3. Recommendations for self-manufacturing of ISI
8.4. Calculation of the forward converter transformer
8.5. Transformer manufacturing
8.6. Calculation of power losses on the transistors of the converter
8.7. Calculation of the welding current filter choke
8.8. Simulation of converter operation
8.9. Current transformer calculation
8.10. Calculation of the galvanic isolation transformer
8.11. PWM controller TDA4718A
Control unit (CU)
Voltage Controlled Generator (VCO)
Sawtooth voltage generator (SPG)
Phase comparator (FC)
Count trigger
Comparator K2
Shutdown trigger
Short circuit comparator
Comparator K4
Soft start
Error trigger
Comparators K5, K6, K8 and VRF overcurrent
Comparator K7
exits
Reference voltage
8.12. Control unit for inverter welding source "RytmArc"
circuit diagram
Control unit nodes
8.13. Formation of the load characteristic of the source
The main sections of the CVC
Means for the formation of the CVC
CU setting method
8.14. Using an alternative PWM controller
Replacements for the outdated TDA4718A PWM controller
Features of the TDA4718A chip
8.15. transformer driver
Chapter 9
9.1. How to test unknown iron?
9.2. How to calculate a transformer?
9.3. How to calculate a core choke?
Calculation features
Calculation example No. 1
Calculation example No. 2
Calculation example No. 3
9.4. How to calculate the radiator?
9.5. How to make welding electrodes?
List of used literature and Internet resources