SOFT SWITCHING INVERTER POWER SOURCE FOR ARC WELDING

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1 SOFT SWITCHING INVERTER POWER SOURCE FOR ARC WELDING H. Mecke, W. Fischer, F. Werher Oo-von-Guericke-Universiy Magdeburg, Insiue ELE, Germany Absrac. Modern elecronic power sources for arc welding are mosly based on he inverer principle. The increase of swiching frequency o abou khz is desirable for furher improvemen of conrol capabiliies and o reduce dimensions and weigh and can only be reached sufficienly wih sof swiched semiconducors. A new conrol mehod has been developed for he ZVZCS - PS - FB - converer considering he specific saic and dynamic load condiions of arc welding. Simulaion resuls and experimenal verificaion give good operaion condiions over he enire load range. Keywords. arc welding power source, sof swiching, PS - ZVZCS - FB - converer, load adaped conrol INTRODUCTION CIRCUIT TOPOLOGY AND BASICS OF OPERATION Elecronic conrolled power sources are widely used in he indusrial applicaion of differen arc welding processes. The increase of he swiching frequency from 5 Hz of a phase conrolled recifier o abou...6 khz of a modern ransisor conrolled inverer allowed o reduce weigh and dimensions of arc welding power sources dramaically. Furhermore, a precise conrol of he arc welding process wih is complexiy of hea inpu, maerial ransfer and arc behaviour could be achieved []. For example, during sriking of he arc here are wo condiions wih differen requiremens o he power source, he no load volage of abou 5 V and he rapidly rising arc curren. To achieve conrolled drople ransfer i is necessary o swich he curren level from abou A o 5A wihin less han µs for a pulse ime of ms and a pulse frequency of Hz. Today he asymmerical half-bridge-forward-converer became he favourie opology of an inverer power source. For higher oupu power, wo sages are used in parallel, a he dc-inpu and he dc-oupu wih 8 phase-shifing []. Hard swiched IGBTs or MOSFETs wih dissipaive snubbers are mosly used as power swiches dependen on supply volage and oupu power range. The swiching losses limi he useable swiching frequency. For his reason, he reducion of swiching losses wih resonan or sof swiching opologies are necessary. Arc welding power sources have o keep some requiremens wih regard o reducion of swiching losses, ha resuls from he characerisic of an arc welding process: exremely wide load range from no load o shor circui condiions exremely wide conrol range of load curren o influence he welding process realisaion of fas load curren changes From hese requiremens i is recognisable, ha he mode of operaion of he snubbers mus be independen from he load condiions o operae enire wihou any swiching losses. As our invesigaion based on simulaion resuls have shown convenional resonan and sof swiching opologies are parly conneced wih considerable drawbacks like: swiching losses a urn-off, resonan effecs (series resonan converer above resonance) [], [4] difficulies in achieving a wide power range wihou any swiching losses (quasiresonan ZCS) [5] high expendiure due o auxiliary circuis (muliresonan ZCS, ZVT) [7], [8] low load currens (ZCS-PS-FB-converer) [6] A new opology ha mees he requiremens of arc welding wih is dynamically changing load condiions is he PS-ZVZCS-FB-converer as inroduced in [8], Fig.. S ic S S A CR CR VCE S VLS LS CB VCB S i CB S4 ic S4 B VCE S4 ARC LOAD Fig. : Circui opology of a PS - ZVZCS - FBC wih arc load [8] Wih his circui based on a full bridge opology i is possible o conrol he primary volage of he ransformer by shifing he phase beween he wo halfbridge legs. In conras o he sandard ZVS-PS-FB-converer a saurable inducance and a blocking capacior are conneced in series wih he ransformer. Only wo parallel conneced capaciors across he ransisors of one leg are necessary, insead of four capaciors in he sandard opology. The basic idea of he conrol mehod is o achieve ZVS condiions for one leg and ZCS condiions for he oher [8]. Fig. shows he sandard conrol diagrams [8] and idealised swiching waveforms a high load curren from he PS-ZVZCS-FBC wih arc load, assuming ideal swiches S - S 4 and diodes D - D 4, an idealised ransformer wih a discree leakage inducance L TrL a he primary side, an ideal saurable inducor L S (wihou hyseresis, wo swiching condiions wih a linear characerisic) and a consan load curren I L. These waveforms can be divided ino seven characerisic inervals o analyse circui operaion in he bridge diagonal for boh direcions (S/S4, S/S). Time inerval T ( ): A he ime he ransisor S is urned on, while he ransisor S 4 was already swiched on. The sill unsauraed inducor L S (L S >>L TrL ) limis he rise of he ransisor curren i CS4 a a very low value. A sof urn-on is achieved in his way. The inermediae circui d.c. volage is across he saurable inducor now and he ferrie core becomes sauraed. T is finished when L S is sauraed. Time inerval T ( ) The curren i CB is rising linearly owards he refleced oupu curren i CB I' L I L /m, limied hrough he leakage inducance of he ransformer L TrL. LD IL

2 V GE S BASIC DESIGN CONSIDERATIONS V GE S V GE S Snubber capaciors V GE S4 V AB icb The snubber capacior design is from a decisive imporance for he effeciveness of he urn-off swiching loss reducion for he ransisors S and S and for he conrollabiliy of he inverer. The urn-off swiching losses P VSoff can be calculaed for he ransisors S /S as a funcion of C R assuming ha he ransisor curren is falling linearly, Fig.. V CB V CE S ic S M K icr S V CR () I CB / D i CR I CB V CR () ICB ics VCES icr icr i CR VCES f V CE S 4 4 i C S4 Fig. : Equivalen circui for urn-off swiching loss reducion a ransisor S V LS Two cases are o be disinguished: Fig. : Conrol diagram and swiching waveforms a nominal load condiions Time inerval T ( ) During T he energy ransfer from of he inermediae d.c. circui ino he load akes place. The volage across he blocking capacior C B is rising nearly linearly from -V CBm o V CBm. The capacior can block any occurring d.c. volage across he ransformer by soring he energy differences. Tha could be a resul from unequal overlap angles beween he on - imes of he ransisors in boh bridge diagonals (α S/S4 in relaion o α S/S ). T is finished when S is urned off. Time inerval T4 ( 4 4 ) The snubber capaciors C R / C R are charged/ discharged by he curren i CB beginning a he ime. For his reason he rise of he ransisor volage is limied and he ransisor is urning off sofly. The energy ransfer is compleed, when he secondary ransformer volage ges below he oupu load volage. The freewheeling period begins a his ime and he ransformer is being shored. The ime inerval T4 is finished when D is conducing. () C R > C Rcri : (The snubber capacior volage reaches he inermediae circui d.c. volage afer i CS has reached zero.) ICB f P W f C f VSoff VSoff S 48 () C R < C Rcri : (The snubber capacior volage reaches he inermediae circui d.c. volage before i CS has reached zero.) f V d P VSoff I C f V C CB f d R VC d R S R ICB f I I ICB f CRcri 4 V R S CB f CB - fall ime of he ransisor curren - inermediae circui d.c. volage d VC I d R CB f Fig. 4 shows he calculaed swiching losses P VSoff for boh cases versus he capaciance of he snubber capaciors. I is obvious ha he reducion of urn-off swiching losses wih C R >> C Rcri is insignifican. Therefore i is mos suiable o design C R C R C Rcri. Time inerval T5 ( ) The volage across he ransisor S is clamped a zero by he diode D. The ransisor S can be urned on wih zero volage across i (ZVS). The volage V CBm appears across he inducors L TrL and L S (sauraed). Therefore he primary curren is falling linearly. The ime inerval T5 is finished when he diagonal curren i CB urns back is direcion and D urnsoff as a resul. Time inerval T6 ( ) The inducor L S is no sauraed any more. Therefore i is blocking he diagonal curren on very low values and he discharge of he blocking capacior is prevened. The ransisor S 4 can be urned off wih a curren close o zero (ZCS). The ime inerval is finished when S 4 is urned off. PVS (W) Fig. 4: CRcri CR (nf) Calculaed swiching losses of S (IRGPC5U) ( f ns - collecor curren fall ime) Saurable inducor PVS on ( IL ) PVS off (IL A) CR < CRcri CR > CRcri Time inerval T7 ( ) This ime inerval is necessary o allow he recombinaion of he remaining charge carriers a he inner p.n.-juncion of he IGBT S 4. The ransisor reaches is blocking capabiliy faser han wihou ZCS. The inerval is finished when S is urned on. The saurable inducor is required o preven he discharge of he blocking capacior during he ime inervals 6 7 and o limi he curren rise afer he ransisors S /S 4 are urned on. For his reason i is no allowed ha he inducor sauraes during hese ime inervals. The ferrie core cross-

3 secional area A els and he number of windings N LS, required for his condiions, can be calculaed as an approximae value from he linearisied inducor volage waveforms during he ime inervals 6 7, Fig.. A els N LS ( ) ( ) VCBm max VCBmmax B 6 7 sals Some of he calculaed conrol characerisics are shown in Figure 6. They allow o esimae he influence of he passive componens on he conrollabiliy of he load curren. The influence of he snubber capaciors is of grea imporance for he conrol range of he power source. Their increase courses a decrease of he required overlap angle for a given load curren because of he higher amoun of he sored energy in hese capaciors. B sals - sauraion flux densiy of ferrie core IL (A) Blocking capacior The diagonal curren fall ime depends on he leakage inducance value, he overlap angle beween he on-imes (means 4 ), he saurable inducor and he blocking capacior α (deg) 8 5 [ ] C L L B Ssa TrL 4 The maximum volage across he blocking capacior can be calculaed as a funcion of oupu curren: Fig. 6: RL,5Ω, CR nf, V arc, fs 5kHz, Ri,Ω RL,44Ω, CR 5nF, V arc, fs 5kHz, Ri,Ω RL,5Ω, CR 5nF, V arc, fs 5kHz, Ri,Ω 4 RL,5Ω, CR 5nF, V arc V, fs 5kHz, Ri,Ω 5 RL,5Ω, CR 5nF, V arc, fs khz, Ri,Ω Calculaed conrol characerisics V CBm ( ) IL mc 4 B The maximum volage across he blocking capacior V CBm mus be low o reduce ferrie core cross-secional area of he saurable inducor. The blocking capacior should be designed as a compromise beween a relaively low maximum volage across he blocking capacior V CBm and a shor diagonal curren fall ime 5. For his reason a small leakage inducance of he ransformer is mosly imporan. Conrol funcion For he design of he closed-loop curren conrol and for he selecion of an appropriae driving pulse paern i is of grea imporance o describe he dependence of he adjusable overlap ime on respecively he overlap angle α on he load curren analyically. Considering he design of he passive componens and assuming linearised waveforms according o he equivalen circuis in Fig. 5 he conrol funcion is o be found wih: α 6 TON fs m V R I 4 mv C arc L L d R f α 6 fs m Ri IL IL f S m N LS A els L I mn A B mv TrL L LS els sals d - swiching frequency - urns raio - number of urns of saurable inducor - core cross-secional area of saurable inducor energy ransfer inerval I L free wheeling inerval Wih greaer overlap angles he influence of he snubber capaciors decreases. Higher swiching frequencies a he same load curren require an increase of he overlap angle, because he ime inervals, and 4 remain consan, while he ime period of he conrol signal decreases. In his way, i becomes clear ha a maximum swiching frequency exiss for a specific circui design, oupu power and dimensioning of he passive componens. CONTROL METHOD The developmen of an adaped conrol mehod for he PS-ZVZCS-FBconverer was an essenial subjec of research. A load-relaed conrol has o guaranee low-loss swiching a he power ransisors for all load condiions. The ransisors S and S may only be urned on afer he capaciors C R and C R were discharged compleely. The discharge occurs hrough he load curren refleced o he primary side. If he load curren is on a low value his can ake a relaively long ime or if i is zero a discharge is impossible. While he nex urn-on, he capaciors are discharged direcly via he ransisors. In his case he sored energy is convered ino dissipaive hea, depending on heir capaciance, Fig. 4: P VSon CR fs To avoid hese losses i is necessary o adap he conrol concep o he requiremens of he arc load. For his purpose, he volages across he snubber capaciors and across he oupu are checked. The driving pulse for he ransisor S or S respecively, generaed by he phase shif resonan conroller (PSRC) is blocked unil he corresponding capacior C R or C R is discharged. This can be achieved very simply in he pracical circui design by blocking he driving sages of S /S. CB VCB LD V LD LD V LD V arc I L V arc arc load Ri VR i RL V R L RL V R L Fig. 5: Equivalen circuis for he calculaion of he conrol funcion

4 VOUTB NORM: M S/s 997// :6:4 5ms/div VGE S VOUTA VGE S VGE S VGE S4 VCR (IL ) VCR (IL ) Fig. 7: TON TSON On-imes T SON of he ransisors S and S a differen load currens This modified conrol mehod is uncriical for he operaion mode of he power source, because he ime inervals necessary for he energy ransfer and for ransisor proecion are no influenced negaively, Fig.7. A no load condiions, he capaciors are no discharged any more and he ransisors S and S are no urned on, so ha he circui operaes as a symmerical half-bridge, Fig. 8. The curren regulaor generaes a minimal overlap angle under hese condiions. The welding arc is ignied by a shor conac beween he welding elecrode and he workpiece. This even is deeced by a volage sensor. If he arc volage becomes lower han a reference value he blocking of he ransisors S and S is deacivaed. Afer a delay of some microseconds he curren regulaor operaes a normal condiions o achieve a fas curren rise wihou overshoo. * 4 - il ( 5A / div ) - v L ( V / div ) (wih welding cable) 5 m s/d iv Fig. 9: Measured load curren and volage during ransiion from no-load o shor-circui I is recognisable, ha ransisor S 4 operaes wih nearly no swiching losses and he complee charge changes of he snubber capaciors C R and C R are also visible. The ransisors S and S can urned on wih ZVS in his case afer heir drivers are released. NORM: 5M S/s 997// :6:45 A PS-ZVZCS- FBC V CR / V CR Varc Arc load Curren sensor Low-pass filer - vce S4 ( 5V / div ) - vce S ( 5V / div ) - ic B ( 5 A / d iv ) ( µ s/div ) Fig. : Swiching loss reducion of ransisor S 4 when drivers of S /S are blocked Seings NO RM: 5M S/s 997// :49:5 PSRC and drivers Curren regulaor Fig. 8: Closed-loop adapive curren conrol (block diagram) COMPUTER SIMULATION AND EXPERIMENTAL RESULTS An experimenal welding power source wih a maximum oupu power of,5 kw wih V a.c. single phase line inpu has been buil up o verify he correc operaion mode of he newly developed conrol mehod, o analyse swiching losses, efficiency and dynamic properies. The passive componens of he experimenal power source have been designed as follows: C R C R 7,5 nf C B, µf (V CBm 6 V) L S, mh (L Ssa,56 µh) L TrL,7 µh m 4 Fig. 9 shows he measured curren and volage waveforms a he oupu during a load ransiion from no-load o shor circui condiions wihou overshoo. Fig. shows he volage waveforms across he ransisors S and S 4 and he curren hrough S 4 afer he welding elecrode has ouched he workpiece and before he curren regulaor and he drivers for S and S are released (ransiion from no-load o shor-circui). 4 - v CE S4 ( 5 V / d iv ) 4 - vce S ( 5V / div ) - i CB ( 5 A / d iv ) - v G E S ( V / div ) ( µ s /d iv ) Fig. : Swiching loss reducion of ransisors S and S 4 a low load condiions (I L A) N O RM: 5M S/s 997// :: - il ( 5 A / d iv ) - vl ( 5 V / d iv ) ( 5 µ s / div ) 4

5 Fig. : Load curren and volage during ransiion arc load o shor-circui and vice versa from Fig. 5: Curren, volage and power waveforms of S during ransiion from shor-circui o arc load (simulaed) Fig. shows he adapaion of he driver signals of S a lower load curren ( I L A ). Fig. and Fig. show he load curren and volage waveforms during a shor ime elecrode shor circui wih a following reigniion of he arc. As experimenal resuls have shown during all criical phases of dynamic load changes he conrol mehod guaranees a loss-less respecively a low-loss swiching performance of all ransisors. η,6,4 η o η inv The resuls of pracical invesigaion have been confirmed by simulaion. The used mixed-mode simulaor SABER is suiable for he simulaion of he power sage wih IGBTs, conrol and load. The simulaion sysem allows he adequae accurae reproducion of properies of he IGBT IRGPC5U by using is simulaion model. 4 NORM: M S/s 997// 7::5, I L (A) Fig. 6: Inverer and oal efficiency of he experimenal arc welding power source The experimenal power source realises a maximum oupu power P Lmax,5 kw and an efficiency η,9 beween 4% and % of he nominal load. I is possible o use IGBTs of he ype IRGPC5U wih a swiching frequency beween 5 khz and 8 khz, [9]. 4 CONCLUSIONS - v CE S ( 5V / div ) - vce S4 ( 5V / div ) - v GES ( V / d iv ) 4 - icb ( A / d iv ) ( µs /d iv ) Fig. : Volages across ransisors S and S 4 and primary ransformer curren a ransiion from shor-circui o arc (zoomed from Fig. ) p (W ) v (V) i (A) load The PS-ZVZCS-FB-opology conneced wih he developed conrol mehod wih a dynamic adjusmen of he impulse sequence depending on load condiions makes i possible for he power ransisors of an arc welding power source o operae wih nearly no swiching losses over he enire conrol and load ranges. Addiional componens on power sage are no required, compared o he opology ha was presened in [8]. Measuremens a an experimenal power source and resuls from compuer simulaion verified, ha he power ransisors operae, even a fas load changes, wih nearly no swiching losses. ics4 References vce S 4.5k 5 5 p V S 4. Norrish, J.: Arc welding power sources - Design evaluaion and welding characerisics, Inernaional Insiue of Welding (IIW), 99, Doc. XII k -5 55u 558u 564u 57u 576u (s) Fig. 4: Curren, volage and power waveforms of S 4 during ransiion from shor-circui o arc load (simulaed) Simulaed and measured waveforms can be compared from Fig. - Fig. 5. The effec of swiching losses reducion is recognisable from he simulaed waveforms of power losses in he ransisors. Merely small urn off swiching losses in he ransisors S and S are o be seen. The secondary recifier-bridge and wiring causes relaively high power losses as shown in Fig. 6. The leakage inducance of he ransformer limis he aainable swiching frequency in his experimenal power source. p (W ) v (V) i (A). Mecke, H.; Merfer, I.: Improvemen of he dynamic performance of inverer ype welding power supplies by auxilary curren sources in he oupu circui, elecronica 94, Munich, 994, pp Pollock, H.; Flower, J.O.: Design, simulaion and esing of a series resonan converer for pulsed load applicaions, PEVD 94, 994, London, pp Malesani, L.; e al.: Elecronic welder wih high-frequency resonan converer, IEEE Conf. Ind. Appl. (IAS) 99, Torono, pp Theron, P.C.; e al.: Welding power supplies using he parial series resonan converer, IECON 99, pp. 5-.5k 5 ics vces 6. Hua, G.; Lee, F. C.: Novel full - bridge - zero - curren - swiched PWM converer, EPE 9, 99, Firenze, pp p VS 7. Hua, G.; Lee, F. C.: Sof-swiching PWM echniques and heir applicaions, EPE 9, Brighon, 99, pp. III/ k Jovanovic, M.M.; Lee, F.C.: Resonan and sof-swiching converers, Lecurer noes, March 6-7, 995, chapers 4, 6 55u 558u 564u 57u 576u (s) 9. Werher, F.: Resonanzwandler für das Lichbogenschweissen, Diploma hesis, Oo-von-Guericke-Universiy Magdeburg, 997 5

6 Addresses of he auhors Prof. Dr.-Ing. habil. Huber Mecke, Dr.-Ing. Wolfgang Fischer, Dipl.-Ing. Frank Werher Oo-von-Guericke-Universiy Magdeburg Insiue of Elecrical Engineering and Power Elecronics (IELE) P.O. Box 4 D-96 Magdeburg, Germany Tel.: (49 9) Fax.: (49 9)

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