Inverter Welder vs Transformer Welder

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  • เผยแพร่เมื่อ 21 ต.ค. 2024
  • In this episode of The Longevity Learning Lab, Bruce goes in deeper to define inverters and transformer welder machines and what the differences are between them.
    Transformer
    A transformer-style welding power supply converts the moderate voltage and moderate current electricity from the utility mains (typically 115 or 230 volts in the US) into a high current and low voltage supply, typically between 17 to 45 (open-circuit) volts and 55 to 590 amperes. A rectifier converts the AC into DC on more expensive machines.
    This design typically allows the welder to select the output current by variously moving a primary winding closer or farther from a secondary winding, moving a magnetic shunt in and out of the core of the transformer, using a series saturating reactor with a variable saturating technique in series with the secondary current output, or by simply permitting the welder to select the output voltage from a set of taps on the transformer's secondary winding. These transformer style machines are typically the least expensive.
    The trade against being the least expensive is that pure transformer designs are often bulky and massive because they operate at the utility mains frequency of 50 or 60 Hz. Such low frequency transformers must have a high magnetizing inductance to avoid wasteful shunt currents. The transformer may also have significant leakage inductance for short circuit protection in the event of a welding rod becoming stuck to the work piece. The leakage inductance may be variable so the operator can set the output current.
    Inverter:
    Since the advent of high-power semiconductors such as the insulated gate bipolar transistor (IGBT), it is now possible to build a switched-mode power supply capable of coping with the high loads of arc welding. These designs are known as inverter welding units. They generally first rectify the utility AC power to DC; then they switch (invert) the DC power into a stepdown transformer to produce the desired welding voltage or current. The switching frequency is typically 10 kHz or higher. Although the high switching frequency requires sophisticated components and circuits, it drastically reduces the bulk of the step down transformer, as the mass of magnetic components (transformers and inductors) that is required for achieving a given power level goes down rapidly as the operating (switching) frequency is increased. The inverter circuitry can also provide features such as power control and overload protection. The high frequency inverter-based welding machines are typically more efficient and provide better control of variable functional parameters than non-inverter welding machines.

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