Conference Paper

Modeling of Power Supply for Welding with Power Factor Correction

Authors:
  • Priazovskiy state technical university, Mariupol, Ukraine
  • Priazovskyi State Technical University
  • Priazovskyi State Technical University, Ukraine
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This paper presents and analyzes an AC-DC power converter structure, which is comprised of a Power Factor Correction (PFC) module and a LLC resonant DC-DC converter module. This converter only uses two switches, and requires three less diodes and one less switch compared to popular LLC resonant converter solutions. Compared to its conventional counterpart, the rectifier of interest has high energy efficiency while a smaller size, owing to the soft-switching in the LLC resonant converter. Detailed theoretical analyses are conducted in this study, followed by software simulation and hardware experimentation, which demonstrate that the single stage double-switched (DS)-LLC rectifier is able to realize unity power factor and a wide output range, indicating its effectiveness and applicability.
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Purpose. Development of a three-phase power supply for a single-phase resistance welding machine (RWM). The presented power supply utilizes active power factor correction and draws balanced grid currents. Usage of such power supplies allows ensuring electromagnetic compatibility of the RWM with the power grid. Methodology. A mathematical model of the three-phase power supply for single phase RWM based on the frequency converter with direct coupling is developed. The model accounts for welding circuit parameters. Converter input and output currents, converter output voltage are shown. The following power quality parameters of the developed RWM power supply are calculated: power factor, harmonic distortion of input currents, negative sequence current ratio. Findings. To ensure minimum power losses in the power grid, RWM power supply should present a symmetrical active load to the supply network. In case of symmetrical mains voltages, the consumed instantaneous active power is constant. On this basis, the RWM power supply converter operates in a rectifier mode providing constant power to the load. To avoid RWM transformer biasing and to prevent saturation of its magnetic core, the polarity of the converter output voltage is periodically changed. Thus, the primary voltage of the transformer has a form close to rectangular. Formation of the inverter output voltage with a predetermined amplitude and frequency is done by six bidirectional switches with pulse width modulation control. The developed control method allows controlling converter input currents to be proportional to the corresponding phase voltages. Originality. The theoretical basis for the creation of new RWM power supplies with high energy efficiency and electromagnetic compatibility with the power grid is proposed. Practical value. The use of the direct matrix type converter with developed control algorithm for RWM supply makes it possible to ensure the power supply electromagnetic compatibility with the power grid and to improve its energy efficiency by forming symmetrical input currents and eliminating reactive component of the input currents.
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In this paper, a two-stage on board battery charger is proposed for plug-in electric vehicles (PEVs). An interleaved boost topology is employed in the first stage for power factor correction (PFC) and to reduce total harmonic distortion (THD). In the second stage, a half bridge LLC multi-resonant converter is adopted for galvanic isolation and dc-dc conversion. Design considerations are discussed focusing on the reducing the charger volume, and increasing conversion efficiency over the wide battery pack voltage ranges. Detailed design procedure is provided for a 7.6 kW prototype, charging the battery with an output voltage range of 320 V to 420 V from 240 V, 60 Hz single phase grid. Results of the analyses show that the first stage PFC converter achieves THD less than 4% and power factor higher than 0.99, and the second stage LLC converter operates with high efficiency over the full output voltage range under ZVT.
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In order to solve the power consumption problem of the filament supply in the Electron beam welding system, the character of series resonant converter at a switching frequency of less than 1/2 of the resonant frequency with a constant current output and the feature of soft switch is utilized. As a result, a full-bridge LLC resonant converter, in combination with pulse frequency modulation control method is presented in this paper. Then, a soft-switching type, DC input 48V, 0∼.15A DC output adjustable by setting the filament power supply prototype is designed. The power supply design process and the experimental results show that the power supply prototype solves the heat problem of inverter well and also improves the inverter's efficiency. Finally, some means are introduced to handle the problem of inflated load voltage.
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This paper proposes a novel single-stage LLC resonant ac-dc converter with power factor correction feature. The proposed circuit is the integration of a buck-boost type power factor corrector and an LLC resonant dc-dc converter. The proposed single-stage converter which has power factor correction and output voltage regulation features can simplify circuit complexity, reduce cost, and increase system reliability over conventional two-stage systems. Experimental results of a 100 W prototype are used to verify the feasibility and validity of the theoretical predictions.
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