Technical solution for realisation of arc welding
devices with low influence on power grid
Tirsu Mihai, Zaitev Dmitrii, Calinin Lev,
Berzan Vladimir, Uzun Mihail
Institute of Power Engineering of Academy of Sciences of
Moldova, Chisinau, Republic of Moldova
e-mail: Tirsu.mihai@gmail.com
AbstractThe new technical solution of small capacity arc
welding devices is presented. Proposed technical solution is
original and has small influence on supplying power network.
The key element in proposed technical solution is special
designed algorithm for management of current pulse source
combined with battery as buffer. The output module is a high
frequency converter with adjustable welding current and
interconnected with current pulse source. Discussed technical
solution has a small level of harmonics and flicker.
Index Termsarc dischargers, current control, DC-DC power
converters, power system harmonics, welding.
I. INTRODUCTION
Electric arc welders are certainly not a friend to power
quality. Among the primary issues associated with the arc
welding process is a sudden inrush current demand. Arc
welders draw high levels of inrush current during their
operating cycle, which is often only several seconds in
duration. These high cycle-to-cycle currents cause the flux
(magnetizing current) of the upstream transformer to saturate.
Flux saturation causes the transformer output voltage to drop
precipitously and results in failure or poor performance of the
load. Additionally, if the connection point of welding device is
far from transformer and capacity of distribution lines is
limited, these currents cause the increased active losses in
power lines and essential drop of voltage. This phenomenon
can damage electronic equipment and household appliances
especially of consumers connected close to the point of
welding device connection.
Second, theres the intermittent operation for short
intervals of time. When the weld is first struck, the welder
requires essentially infinite current for a few cycles [1].
During this period, the electrical system providing the power
cannot provide all of the current demanded. The result is
voltage sag in the power line. Simultaneous operation of
multiple welders compounds the voltage sag problem.
Finally, theres variability of the arc cycle-to-cycle. The
first strike of the welder is especially unpredictable. This
Spivak Victor, Sheleaghin Vladimir
Department of Industrial Electronics, National Technical
University of Ukraine Kyiv Polytechnic Institute, Kyiv,
Ukraine
results in a difficult-to-define harmonic spectrum. As the weld
begins to flow, the harmonic spectrum is more predictable
with less amplitude of the peak current. However, the
harmonic current still cannot be predicted. This
unpredictability, in addition to the very high cycle-to-cycle
peak currents at first strike, makes selection of a harmonic
mitigation method extremely difficult. If the harmonics are not
mitigated, they can cause excess heat in the network.
Currently exists a large diversification of welders [2],
starting with traditionally technical solution based on
transformers operating on industrial frequency and finishing
with technical solutions based on high frequency converters.
But, regardless of technical solution, welders has a negative
influence on energy quality, and this influence is more hard if
device is connected near the end of the line.
The paper show new technical solution capable to
decrease, practically, totally negative influence on power
quality. The proposed solution is patented.
II. PROBLEM IDENTIFICATION
Arc welding installation belongs to the class of equipment
with power consumption highly variable in time. When first
strike takes place the current is highest and the installation
working, practically, in short-circuit mode. During the
welding process current can changing its value randomly
around the selected value. Due to the specific peculiarities of
the welding process within operating time installation
inducing a large spectrum of harmonics in network of
different amplitudes. The amplitude of induced harmonics
depends very close of both, the parameters of welding
installation, as well as connection point to network. It should
be noted that welders based on transformers operating directly
on industrial frequency (50Hz/60Hz) has the more negative
influence on energy quality than welders based current
invertors using high frequency conversion.
This paper addresses most the issues related to connection
point of welder to network in dependence of distance from
power substation and its capacity. Schematically, the alternative current in direct current); PCS pulse current
analyzed configuration is shown on the fig.1. source that works by a special program determined by welding
current and voltage level of battery; BT battery that serves as
buffer for compensation of high frequency current demand;
CA current adjustment module that serving for selection of
welding current; BC battery controller that sending
information to PCS about state of battery.

IV. DESCRIPTION OF FUNCTIONING

The supplying voltage of 220V, alternative current is
applied on the input of rectifier module (R) consisting of four
diodes. The rectified voltage is passed through filter (F) to
decrease voltage pulses. In essence this filter is of LC type and
besides of main function of the voltage smoothing has the role
to decoupling network of welding installation. After the
voltage was filtered it is applied on input of pulse current
Figure 1. Typical connection of welding installation away from the source (PCS). This module is one of the most important and
substation key function is to minimize influence of welding installation
Fig.1 represents a common distribution network for rural on network. The special designed algorithm is used to achieve
areas and usually the capacity of substation doesnt exceed this effect. The block-scheme of this algorithm is shown on
100kVA or 160kVA. The length of distribution lines ranks fig.3.
between (1-2) km. For such configuration of distribution lines START
the most dangerous situation appears when welder is
connected on the end of line as shown in fig.1. During No
welding process the voltage around connection point can drop Iw>0
very substantially (some time below 160V). When process is Yes
stopped voltage can increasing significantly above allowed Proceeding
Waiting t1 battery charge
level. These drops and raises of voltage occur with high
algorithm
frequency [3] and can damage household appliances of No
neighbor consumers. Iw>0
The situation becomes even more critical when working Yes Is battery
few welding installations simultaneously. In this case quality Current linear full?
of energy is essentially affected. In order to overcome this growth begins
Yes
issue it is necessary to identifying an original technical
solution. No Waiting till
Iw>0 and start
IPCS> Iw
algorithm
III. TECHNICAL SOLUTION OF WELDING INSTALLATION
Yes
Mentioned above problem can be overcome using as Keep current
buffer a small capacity battery in combination with pulse
current source works by a special algorithm. The functional
block-diagram of proposed technical solution is shown on No
Iw=0
fig.2.
Yes
Waiting t2
BC

Uout Linear decease current

~220V
R F PCS BT DC/DC

Figure 3. The block scheme of PCS algorithm

CA
Figure 2. Functional block-diagram of welding installation
R- rectifier; F filter; PCS Pulse Current Source; BT battery; DC/DC
direct current converter; CA current adjustment; BC battery controller
The proposed technical solution of arc welding installation
consists of few modules: R rectifier that rectifying input
voltage 220V; F filter for voltage smoothing (conversion of
The fig.3 describe in details functioning peculiarities of
pulse current source. This module has two inputs: chosen
welding current and voltage level of battery. Depending on
these two parameters the corresponding functioning mode of
PCS is selected.
Let say, that initially the welding process is not started
(Iw=0). In this case the PCS starting battery charging process
that was divided in four steps. The charging process begins
with linear growth of charging current till the value I4 during
period t0-t1(see fig.4).
I
I6
I5
I4
I3
I2
I1
t power network.
t0 t1 t2 t3 t4 t5 t6 t7 t8 t9 t10 t11 t12 t13
Figure 4. Operating mode of PCS
The time t1 is equal to few seconds. When the charging
current reached value I4 it is kept by the time t4. This time t4
can be different and depends of three parameters: state of
battery when charging process begins, it capacity and chosen
strategy of charging. As above was mentioned for paper case
it was selected four steps charging strategy. At first step
battery charging begins with maximal allowed current stated
by technical data. This current is kept until the battery voltage
reach maximal allowed voltage. For example, the battery of
12V has maximal allowed voltage of 14V. Second step
continued with current I3 that is on 30% less than I4. In
moment when we will move to current I3 (during period t3-t4)
the battery voltage will drop a little function of internal
resistance. The charging process will continue until the time t6
when battery voltage again reaches maximal voltage. Third
step begins at t7 with current I2 which value is 60% less than I4
and is finished at time t9. The last fourth step begins at
moment t10 with current I1 which value is about 10% of I4.
Practically, the time moment t10 constitutes the end of battery
charging process and I1 only compensating battery losses.
It should be noted that moving from one level of current to
another is made smooth that excluding current changes by
jump.
Now, let consider, that welding current is selected equal to
maximal possible I6 and we starting welding process between
t1-t2. The PCS never will start if the welding time not exceeds
5-10 seconds. This condition is implemented in order do not
having frequently changing of current level supplied by PCS.
So, if welding process was started 5-10 seconds before t2 then
PCS will smooth increasing supplied current until the value of
I6 and after keep constant this level. The stopping of welding
process less when some established time tx will not affect the
launched procedure. So, the PCS will keep current I6 until the
welding process will not be stopped for time more than tx.
Now, we consider that welding process was stopped with
tx time before t8. In this case starting from moment of time t8
until moment t9 the PCS will smooth decreases current up to
value I4 maximal allowed charge value. From this moment
the described above charge procedure is followed.
If welding process is started again with tx before time t12
the PCS the procedure will be repeated smooth increasing of
supplied current till value I6 and after keeping it.
Selection of another welding current I5 (0<I5<I6) will be
similar to described process for I6 but maximal value of
current provided by PCS will be equal to I5. If no more
welding process is made than PCS following procedure of
battery charging and after procedure is complete go in standby
mode.
Implementation of such algorithm in operation mode of
PCS allowing us to avoid instant over consumption of power
from network especially in moments of electrode struck and
arc ignition. Smooth increasing and decreasing of consumed
current excluding high frequency disturbance induction in
The last output module is the high frequency converter
(DC/DC) connected directly to battery. The technical solution
of converter can be different depends of battery voltage.
When exists necessity to work direct from car battery or other
machinery, where battery voltage is 12V or 24V, we can use
two module construction of welder. It means, that second
module consisting of only DC/DC converter can be separated
by first module which including all others components and
connected direct to external battery. In this case the DC/DC
converter must including intermediary transformer to raise
output voltage above 60V to ensuring welding process.
The second technical solution can be considered welding
installation as one integral device. In this case it can be used
battery with voltage above 60V. As result, no necessity in
intermediary transformer. The battery voltage can be directly
applied to welding piece through electronic power key and
inductance controlling output current.
So, applying technology presented on fig.4 for
management of PCS and implementing technical solution
shown on fig.3 it is possible to reduce essentially induction of
disturbances in power network by welding installation. From
other side, the harmonics inducted in power network will be
only from PCS, which working frequency is constant and
using PWM management mode to controlling current.
Because frequency is constant, it is possible to calculate exact
parameters of filter and achieve desired parameters of
harmonics. The described technical solution of arc welding
installation is patented by authors in Republic of Moldova [4].
V. BATTERY PARAMETERS
The battery parameters have a very important role in
welding process. The price of installation also is influenced by
capacity of battery and its type. This one should be selected in
function of welder necessity.
It should be noted, that welding process usually is not
continue. As rule, active running time is much less than
staying (pause) time. We denote by k factor of activity:
tactivity
k= . (1)
t pause
Depending on this factor of activity and rated power of
welding installation we can choose respective battery. The
rated power of welding installations used in household sector
and different services companies (like car services) are in
range of (3-5) kW. Coefficient of activity usually not exceed
0,3-0,5. But production of welding installation can be made
function of consumers necessity. In any case, if activity
coefficient is 0,5 spent energy for welding process will be
around of (1,5-2,5) kWh. Here should be considered all losses
as well.
Let consider, that welding installation is of 5kW and
welder not exceed activity coefficient k= 0,5. The energy
spent by him is 2,5kWh. The efficiency of DC/DC converter
is 90%. This means that summary energy consumed by
DC/DC converter will be around 2,75kWh.
Another condition is to know how much time DC/DC
converter works autonomous from battery. This time depends
on implemented algorithm in pulse current source. If we
accept maximal time equal to 1 minute then consumed power
from battery will be 2,75kWh/60minutes = 50Wh, including
battery losses.
From other side, fully charging and discharging cycles of
battery are limited. From this reason, it is good to not
discharge battery more than 20%. Considering this, the battery
capacity will be above 250Wh.
At the same time, the instant current supplied by battery
must be enough for ensuring welding process. Let say, that
battery has voltage level of 60V. In this case the battery
current coincides with welding current.
So, at finally our battery should have current above 5Ah
and instant current above welding current. Also, the selected
battery must allowing quick charging and frequently high
current consumption.
The PCS during welding process must be able to fulfill
battery and keep the constant voltage level of battery.
Generally, the supplied current by PCS must be a little high
than current consumed by DC/DC converter to compensating
energy consumed from battery.
The more detailing studying of relation between battery
capacity, energy spent by welding process and selected
algorithm of PCS functioning is necessary.
The main objective of paper was decreasing of welding
process influence on power quality of network and minimizing
of harmonics level. This objective is achieved by using a
battery as compensation buffer.
CONCLUSION
The new original technical solution for manufacturing arc
welding installation was submitted. This solution has two key
elements: pulse current source operating by special mode and
battery used as buffer.
The special algorithm for pulse current source was
designed. This algorithm excluding current consumption in
jumping mode from network, ensuring smooth increasing and
decreasing of consumed current from network, providing
compensation in time of consumed energy from battery.
The idea of battery capacity calculation and
recommendations on it selection was provided.
ACKNOWLEDGMENT
The researches were made in frame of the bilateral project
Moldova-Ukraine Arc welding installation with reduced
influence on power network.
REFERENCES
Web link:
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American Operating Division, May 2006, http://www.mt-
online.com/may2006/improving-power-quality-in-arc-welding-
applicaitons
[2] http://ro.wikipedia.org/wiki/Sudare
Periodicals:
[3] A. Sawicki, . Switon, And R. Sosinski, "Process Simulation in the AC
Welding Arc Circuit Using a Cassie-Mayr Hybrid Model,"
SUPPLEMENT TO THE WELDING JOURNAL, vol. 90, pp. 42-s-44-s,
March 2011, http://www.aws.org/wj/supplement/wj201103_s41.pdf
Patents:
[4] M. Tirsu, "Arc welding installation," MD Patent MD 4185 C1, June
30, 2013.