254 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Improved Power Quality with Regenerative Approach forWelding Application

Manoj Kumar and Sanjeev SinghElectrical and Instrumentation Engineering Department

SLIET Longowal Punjab (India)

Abstract:This paper proposes Four quadrant converter for single phase welding inverter. To follow the internationalpower quality standards, a regenerative boost converter is used at front end and operated undercurrentcontinuous conduction mode (CCM). To provide the isolation between input/output and to drive the weldingload, a two-switch high frequency forward converter with a hysteresis current controller is employed. Theperformance simulation is carried out on MALTLAB simulink platform and hardware prototype results aredemonstrated to validate the proposed concepts.

INTRODUCTION: Conventional single-phase welding system uses low voltage, high current power supply,consisting of a heavy transformer [1] which results in increased losses and reactive burden on the AC systemwith poor power factor. With the fast-developing power electronic technology [2-4], high efficiency weldingpower supply are in demand with additional features of light weight, robustness, safety, reliability, low costand flexibility of operation. Further, high quality of welding is expected irrespective of the job material andambient conditions (temperature, humidity, etc.). Moreover, sticking of the welding head must be avoided atany current level. In order to meet all these requirements, it is important to ensure: current regulation, in awide range (typically 10%-100% of the rated value), so as to increase equipment flexibility; high operatingfrequency, to minimize transformer weight; good power factor, to reduce the losses in AC system, whilecomplying with existing international standards; fast response, and fault tolerance. These needs are only metby incorporating high-frequency transformers fed by soft-switched inverters[5-9] to the welding power supply.There are publications [10-12] reported for three phase welding power supply, however, little references areavailable for single-phase welding machines. This paper proposes a high frequency AC-DC converter basedpower supply operated from single-phase AC mains to present a light weight, energy efficient and improvedpower quality welding set.

PROPOSED CONFIGURATION: Fig.1 shows the circuit diagram of proposed four quadrant converter forwelding set, with regenerative action [10]. In the proposed four quadrant converter four IGBTs are used tocontrol the DC link voltage Vdc and the power quality at input AC.There are mainly two stages in theproposed improved power quality four quadrant converter for welding inverter. First stage consists of fourswitches, which operate with sine PWM technique. In the second stage isolated two-switch forward converteris used for welding purpose.Arc welding machine provides the required current at various stages of the arc process at varying voltages. Atno load, a high voltage is produced across the terminals of welding set which is called as open circuitvoltage[1]. When the electrode touches to the job, a short circuit occurs and current increases rapidly.Thereafter, when the current reaches the rated value, the arc welding machine regulates the output voltage tomaintain constant current which is essential for homogeneous metal transfer and excellent quality of welding.

254 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Improved Power Quality with Regenerative Approach forWelding Application

Manoj Kumar and Sanjeev SinghElectrical and Instrumentation Engineering Department

SLIET Longowal Punjab (India)

Abstract:This paper proposes Four quadrant converter for single phase welding inverter. To follow the internationalpower quality standards, a regenerative boost converter is used at front end and operated undercurrentcontinuous conduction mode (CCM). To provide the isolation between input/output and to drive the weldingload, a two-switch high frequency forward converter with a hysteresis current controller is employed. Theperformance simulation is carried out on MALTLAB simulink platform and hardware prototype results aredemonstrated to validate the proposed concepts.

INTRODUCTION: Conventional single-phase welding system uses low voltage, high current power supply,consisting of a heavy transformer [1] which results in increased losses and reactive burden on the AC systemwith poor power factor. With the fast-developing power electronic technology [2-4], high efficiency weldingpower supply are in demand with additional features of light weight, robustness, safety, reliability, low costand flexibility of operation. Further, high quality of welding is expected irrespective of the job material andambient conditions (temperature, humidity, etc.). Moreover, sticking of the welding head must be avoided atany current level. In order to meet all these requirements, it is important to ensure: current regulation, in awide range (typically 10%-100% of the rated value), so as to increase equipment flexibility; high operatingfrequency, to minimize transformer weight; good power factor, to reduce the losses in AC system, whilecomplying with existing international standards; fast response, and fault tolerance. These needs are only metby incorporating high-frequency transformers fed by soft-switched inverters[5-9] to the welding power supply.There are publications [10-12] reported for three phase welding power supply, however, little references areavailable for single-phase welding machines. This paper proposes a high frequency AC-DC converter basedpower supply operated from single-phase AC mains to present a light weight, energy efficient and improvedpower quality welding set.

PROPOSED CONFIGURATION: Fig.1 shows the circuit diagram of proposed four quadrant converter forwelding set, with regenerative action [10]. In the proposed four quadrant converter four IGBTs are used tocontrol the DC link voltage Vdc and the power quality at input AC.There are mainly two stages in theproposed improved power quality four quadrant converter for welding inverter. First stage consists of fourswitches, which operate with sine PWM technique. In the second stage isolated two-switch forward converteris used for welding purpose.Arc welding machine provides the required current at various stages of the arc process at varying voltages. Atno load, a high voltage is produced across the terminals of welding set which is called as open circuitvoltage[1]. When the electrode touches to the job, a short circuit occurs and current increases rapidly.Thereafter, when the current reaches the rated value, the arc welding machine regulates the output voltage tomaintain constant current which is essential for homogeneous metal transfer and excellent quality of welding.

254 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Improved Power Quality with Regenerative Approach forWelding Application

Manoj Kumar and Sanjeev SinghElectrical and Instrumentation Engineering Department

SLIET Longowal Punjab (India)

Abstract:This paper proposes Four quadrant converter for single phase welding inverter. To follow the internationalpower quality standards, a regenerative boost converter is used at front end and operated undercurrentcontinuous conduction mode (CCM). To provide the isolation between input/output and to drive the weldingload, a two-switch high frequency forward converter with a hysteresis current controller is employed. Theperformance simulation is carried out on MALTLAB simulink platform and hardware prototype results aredemonstrated to validate the proposed concepts.

INTRODUCTION: Conventional single-phase welding system uses low voltage, high current power supply,consisting of a heavy transformer [1] which results in increased losses and reactive burden on the AC systemwith poor power factor. With the fast-developing power electronic technology [2-4], high efficiency weldingpower supply are in demand with additional features of light weight, robustness, safety, reliability, low costand flexibility of operation. Further, high quality of welding is expected irrespective of the job material andambient conditions (temperature, humidity, etc.). Moreover, sticking of the welding head must be avoided atany current level. In order to meet all these requirements, it is important to ensure: current regulation, in awide range (typically 10%-100% of the rated value), so as to increase equipment flexibility; high operatingfrequency, to minimize transformer weight; good power factor, to reduce the losses in AC system, whilecomplying with existing international standards; fast response, and fault tolerance. These needs are only metby incorporating high-frequency transformers fed by soft-switched inverters[5-9] to the welding power supply.There are publications [10-12] reported for three phase welding power supply, however, little references areavailable for single-phase welding machines. This paper proposes a high frequency AC-DC converter basedpower supply operated from single-phase AC mains to present a light weight, energy efficient and improvedpower quality welding set.

PROPOSED CONFIGURATION: Fig.1 shows the circuit diagram of proposed four quadrant converter forwelding set, with regenerative action [10]. In the proposed four quadrant converter four IGBTs are used tocontrol the DC link voltage Vdc and the power quality at input AC.There are mainly two stages in theproposed improved power quality four quadrant converter for welding inverter. First stage consists of fourswitches, which operate with sine PWM technique. In the second stage isolated two-switch forward converteris used for welding purpose.Arc welding machine provides the required current at various stages of the arc process at varying voltages. Atno load, a high voltage is produced across the terminals of welding set which is called as open circuitvoltage[1]. When the electrode touches to the job, a short circuit occurs and current increases rapidly.Thereafter, when the current reaches the rated value, the arc welding machine regulates the output voltage tomaintain constant current which is essential for homogeneous metal transfer and excellent quality of welding.

255 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

The voltage maintained during the steady state condition is proportional to current and the current depends onthe arc length and electrode diameter.

N1

HF Transformer

Cvs

Vdc

is

S1

S2

S3

S4

LsS5

S6D1

D2

N2

D3

D4

Lo

CoLOAD

Io

Vo

Welding Load

Vconv.

Fig. 1. Four switches regenerative active rectifierfor welding inverter

Proposed Control Scheme: The Four quadrant converter control scheme, as shown in Fig. 2, has dc linkvoltage Vdc which is compared with reference Voltage ∗ to generate voltage error Ve. This voltage error isfed to aproportional-integral (PI) controller which is responsible to control the amount of power required tomaintain the dc-link voltage.Input voltage template is used to generate the reference so that the input current is follows the sinusoidal shapeof the vs, however due to polluted vs this task is sometimes impossible. Hence to remove this problem a PLL isused which generates a perfect sinusoidal waveform of frequency that matches to the frequency of inputvoltage vs.

This voltage reference signal is multiplied with voltage error to generate a reference current is* . Thisreference current is* is compared with is to generate the current error. This error signal is fed to currentcontroller, where it is compared with high frequency triangular wave to generate PWM pulses for converter.Fig. 3 shows the operating modes of PWM four quadrant converter for welding inverter for positive andnegative half cycles of the Input AC voltage as shown in Fig. 3a. During positive half cycle of input ACvoltage, switch S1 or S4, body diode of switch S2or S3 are conducting as shown in Fig. 3a.The applied PWMpulses force the input inductor current to follow the sinusoidal shape of input AC voltage and simultaneouslymaintains the DC link voltage effectively.In stage 1 as shown in Fig.3 a(i), during positive half cycle, only the switch S1is ON, the current passesthrough inductor Ls, body diode of S3 and then through S1 to complete the current loop and thereby energy isstored in inductor Ls and given as,= = ( ) (1)

In stage 2, as shown in Fig. 3 a(ii), when the switch S1is OFF, the dc link capacitor C charges with sourcevoltage and energy stored in inductor. The resultant waveforms of inductor current, dc link capacitor voltageand PWM pulse are shown in Fig 4(a).= = ( ) + (2)

255 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

The voltage maintained during the steady state condition is proportional to current and the current depends onthe arc length and electrode diameter.

N1

HF Transformer

Cvs

Vdc

is

S1

S2

S3

S4

LsS5

S6D1

D2

N2

D3

D4

Lo

CoLOAD

Io

Vo

Welding Load

Vconv.

Fig. 1. Four switches regenerative active rectifierfor welding inverter

Proposed Control Scheme: The Four quadrant converter control scheme, as shown in Fig. 2, has dc linkvoltage Vdc which is compared with reference Voltage ∗ to generate voltage error Ve. This voltage error isfed to aproportional-integral (PI) controller which is responsible to control the amount of power required tomaintain the dc-link voltage.Input voltage template is used to generate the reference so that the input current is follows the sinusoidal shapeof the vs, however due to polluted vs this task is sometimes impossible. Hence to remove this problem a PLL isused which generates a perfect sinusoidal waveform of frequency that matches to the frequency of inputvoltage vs.

This voltage reference signal is multiplied with voltage error to generate a reference current is* . Thisreference current is* is compared with is to generate the current error. This error signal is fed to currentcontroller, where it is compared with high frequency triangular wave to generate PWM pulses for converter.Fig. 3 shows the operating modes of PWM four quadrant converter for welding inverter for positive andnegative half cycles of the Input AC voltage as shown in Fig. 3a. During positive half cycle of input ACvoltage, switch S1 or S4, body diode of switch S2or S3 are conducting as shown in Fig. 3a.The applied PWMpulses force the input inductor current to follow the sinusoidal shape of input AC voltage and simultaneouslymaintains the DC link voltage effectively.In stage 1 as shown in Fig.3 a(i), during positive half cycle, only the switch S1is ON, the current passesthrough inductor Ls, body diode of S3 and then through S1 to complete the current loop and thereby energy isstored in inductor Ls and given as,= = ( ) (1)

In stage 2, as shown in Fig. 3 a(ii), when the switch S1is OFF, the dc link capacitor C charges with sourcevoltage and energy stored in inductor. The resultant waveforms of inductor current, dc link capacitor voltageand PWM pulse are shown in Fig 4(a).= = ( ) + (2)

255 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

The voltage maintained during the steady state condition is proportional to current and the current depends onthe arc length and electrode diameter.

N1

HF Transformer

Cvs

Vdc

is

S1

S2

S3

S4

LsS5

S6D1

D2

N2

D3

D4

Lo

CoLOAD

Io

Vo

Welding Load

Vconv.

Fig. 1. Four switches regenerative active rectifierfor welding inverter

Proposed Control Scheme: The Four quadrant converter control scheme, as shown in Fig. 2, has dc linkvoltage Vdc which is compared with reference Voltage ∗ to generate voltage error Ve. This voltage error isfed to aproportional-integral (PI) controller which is responsible to control the amount of power required tomaintain the dc-link voltage.Input voltage template is used to generate the reference so that the input current is follows the sinusoidal shapeof the vs, however due to polluted vs this task is sometimes impossible. Hence to remove this problem a PLL isused which generates a perfect sinusoidal waveform of frequency that matches to the frequency of inputvoltage vs.

This voltage reference signal is multiplied with voltage error to generate a reference current is* . Thisreference current is* is compared with is to generate the current error. This error signal is fed to currentcontroller, where it is compared with high frequency triangular wave to generate PWM pulses for converter.Fig. 3 shows the operating modes of PWM four quadrant converter for welding inverter for positive andnegative half cycles of the Input AC voltage as shown in Fig. 3a. During positive half cycle of input ACvoltage, switch S1 or S4, body diode of switch S2or S3 are conducting as shown in Fig. 3a.The applied PWMpulses force the input inductor current to follow the sinusoidal shape of input AC voltage and simultaneouslymaintains the DC link voltage effectively.In stage 1 as shown in Fig.3 a(i), during positive half cycle, only the switch S1is ON, the current passesthrough inductor Ls, body diode of S3 and then through S1 to complete the current loop and thereby energy isstored in inductor Ls and given as,= = ( ) (1)

In stage 2, as shown in Fig. 3 a(ii), when the switch S1is OFF, the dc link capacitor C charges with sourcevoltage and energy stored in inductor. The resultant waveforms of inductor current, dc link capacitor voltageand PWM pulse are shown in Fig 4(a).= = ( ) + (2)

256 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Loa

d

Ve

VdcS

*

-+

CurrentController

*

PIController

- +

PLL vs ref.

isis

Fig. 2. Four quadrant converter control scheme for welding inverter

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Load

Fig.3(a)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -+

-

Fig. 3. a(i)

256 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Loa

d

Ve

VdcS

*

-+

CurrentController

*

PIController

- +

PLL vs ref.

isis

Fig. 2. Four quadrant converter control scheme for welding inverter

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Load

Fig.3(a)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -+

-

Fig. 3. a(i)

256 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Loa

d

Ve

VdcS

*

-+

CurrentController

*

PIController

- +

PLL vs ref.

isis

Fig. 2. Four quadrant converter control scheme for welding inverter

Cvs

Vdc

is

S1

S2

S3

S4

Ls

Wel

ding

Load

Fig.3(a)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -+

-

Fig. 3. a(i)

257 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+-+

-

Fig. 3. a(ii)

In stage 3, as shown in Fig. 3 a(iii), when the switch S4 is ON, the current passes through inductor Ls,switchS4 and then through body diode of S2 to complete the current loop and thereby energy is stored ininductor Ls. The dc link capacitor C charges as explained in stage 2.

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -

Fig.3 a(iii)Fig. 3a. Regenerative converter for welding inverter operation during positive half cycle 3a (i)-(iii).

Similarly, during the negative half cycle S2 or S3, body diode of switch S1 or S4 conduct as shown in Fig.3b.The resultant waveforms of inductor current, dc link capacitor voltage and PWM pulse shown in Fig. 4(b).

= = ( ) − (3)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+

-

Fig. 3b. Regenerative converter for welding inverter operation during negative half cycle

257 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+-+

-

Fig. 3. a(ii)

In stage 3, as shown in Fig. 3 a(iii), when the switch S4 is ON, the current passes through inductor Ls,switchS4 and then through body diode of S2 to complete the current loop and thereby energy is stored ininductor Ls. The dc link capacitor C charges as explained in stage 2.

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -

Fig.3 a(iii)Fig. 3a. Regenerative converter for welding inverter operation during positive half cycle 3a (i)-(iii).

Similarly, during the negative half cycle S2 or S3, body diode of switch S1 or S4 conduct as shown in Fig.3b.The resultant waveforms of inductor current, dc link capacitor voltage and PWM pulse shown in Fig. 4(b).

= = ( ) − (3)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+

-

Fig. 3b. Regenerative converter for welding inverter operation during negative half cycle

257 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+-+

-

Fig. 3. a(ii)

In stage 3, as shown in Fig. 3 a(iii), when the switch S4 is ON, the current passes through inductor Ls,switchS4 and then through body diode of S2 to complete the current loop and thereby energy is stored ininductor Ls. The dc link capacitor C charges as explained in stage 2.

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+ -

Fig.3 a(iii)Fig. 3a. Regenerative converter for welding inverter operation during positive half cycle 3a (i)-(iii).

Similarly, during the negative half cycle S2 or S3, body diode of switch S1 or S4 conduct as shown in Fig.3b.The resultant waveforms of inductor current, dc link capacitor voltage and PWM pulse shown in Fig. 4(b).

= = ( ) − (3)

C

Vs

Vdc

Is

S1

S2

S3

S4

WELDINGLOAD

Ls

+

-

Fig. 3b. Regenerative converter for welding inverter operation during negative half cycle

258 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

PWM

IL

Vdc

Fig. 4a.Resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM of Regenerativeconverter for welding inverter operation during positive half cycle.

PWM

IL

Vdc

Fig. 4b. The resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM ofRegenerative converter for welding inverter operation during negative half cycle.

PERFORMANCE ANALYSIS OF PROPOSED FOUR QUADRANT CONVERTER FOR WELDINGINVERTER:In this section, the effectiveness of proposed four quadrant converter for welding inverter is evaluated bysimulating the proposed topology in MATLAB-Simulink environment. The proposed converter circuit issimulated to achieve unity power factor and low value of total harmonics distortion.Specifications of Proposed four quadrant converterInput AC mains voltage, vs = 220 V, 50HzSwitching frequency of four quadrant converter fs = 16khzOutput Power, Po: 2 kWOpen circuit output voltage = 80VWelding Output Voltage, Vo =10VOutput Current, Io ≤200ASwitching frequency of DC-DC converter =67khzTransformer primary to secondary turns ratio, N1/N2 = 5.8Input Inductor, Ls = 1.5 mHDc link Capacitor C = 2mFOutput Inductor, Lo: 3.3μH;Output Capacitor Co: 220uFFigs 5-13 show the steady state and dynamic performances of the proposed converter. The converter operatesin CCM to ensure improved power quality and high level of weld quality. The dynamic performance of the

258 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

PWM

IL

Vdc

Fig. 4a.Resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM of Regenerativeconverter for welding inverter operation during positive half cycle.

PWM

IL

Vdc

Fig. 4b. The resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM ofRegenerative converter for welding inverter operation during negative half cycle.

PERFORMANCE ANALYSIS OF PROPOSED FOUR QUADRANT CONVERTER FOR WELDINGINVERTER:In this section, the effectiveness of proposed four quadrant converter for welding inverter is evaluated bysimulating the proposed topology in MATLAB-Simulink environment. The proposed converter circuit issimulated to achieve unity power factor and low value of total harmonics distortion.Specifications of Proposed four quadrant converterInput AC mains voltage, vs = 220 V, 50HzSwitching frequency of four quadrant converter fs = 16khzOutput Power, Po: 2 kWOpen circuit output voltage = 80VWelding Output Voltage, Vo =10VOutput Current, Io ≤200ASwitching frequency of DC-DC converter =67khzTransformer primary to secondary turns ratio, N1/N2 = 5.8Input Inductor, Ls = 1.5 mHDc link Capacitor C = 2mFOutput Inductor, Lo: 3.3μH;Output Capacitor Co: 220uFFigs 5-13 show the steady state and dynamic performances of the proposed converter. The converter operatesin CCM to ensure improved power quality and high level of weld quality. The dynamic performance of the

258 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

PWM

IL

Vdc

Fig. 4a.Resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM of Regenerativeconverter for welding inverter operation during positive half cycle.

PWM

IL

Vdc

Fig. 4b. The resultant waveforms of Inductor current and Capacitor voltage Pattern with PWM ofRegenerative converter for welding inverter operation during negative half cycle.

PERFORMANCE ANALYSIS OF PROPOSED FOUR QUADRANT CONVERTER FOR WELDINGINVERTER:In this section, the effectiveness of proposed four quadrant converter for welding inverter is evaluated bysimulating the proposed topology in MATLAB-Simulink environment. The proposed converter circuit issimulated to achieve unity power factor and low value of total harmonics distortion.Specifications of Proposed four quadrant converterInput AC mains voltage, vs = 220 V, 50HzSwitching frequency of four quadrant converter fs = 16khzOutput Power, Po: 2 kWOpen circuit output voltage = 80VWelding Output Voltage, Vo =10VOutput Current, Io ≤200ASwitching frequency of DC-DC converter =67khzTransformer primary to secondary turns ratio, N1/N2 = 5.8Input Inductor, Ls = 1.5 mHDc link Capacitor C = 2mFOutput Inductor, Lo: 3.3μH;Output Capacitor Co: 220uFFigs 5-13 show the steady state and dynamic performances of the proposed converter. The converter operatesin CCM to ensure improved power quality and high level of weld quality. The dynamic performance of the

259 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

converter has been demonstrated by suddenly switching the welding load. The simulated results for light loadand rated load conditions are shown in Figs. 5-7.

Fig. 5. Dynamic performance of the proposed Four quadrant converter at vs of 220 V

Fig. 6. Waveform and harmonics spectrum of 220V AC mains current (is) at full load

Fig. 7. Waveform and harmonics spectrum of 220VAC mains current (is) at Light load (10%)

259 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

converter has been demonstrated by suddenly switching the welding load. The simulated results for light loadand rated load conditions are shown in Figs. 5-7.

Fig. 5. Dynamic performance of the proposed Four quadrant converter at vs of 220 V

Fig. 6. Waveform and harmonics spectrum of 220V AC mains current (is) at full load

Fig. 7. Waveform and harmonics spectrum of 220VAC mains current (is) at Light load (10%)

259 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

converter has been demonstrated by suddenly switching the welding load. The simulated results for light loadand rated load conditions are shown in Figs. 5-7.

Fig. 5. Dynamic performance of the proposed Four quadrant converter at vs of 220 V

Fig. 6. Waveform and harmonics spectrum of 220V AC mains current (is) at full load

Fig. 7. Waveform and harmonics spectrum of 220VAC mains current (is) at Light load (10%)

260 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 8. Dynamic performance of the proposed Four quadrant converter at vs of 170 V

Fig. 9. Waveform and harmonics spectrum of 170V AC mains current (is) at full load

Fig. 10. Waveform and harmonics spectrum of 170V AC mains current (is) at Light load (10%)

260 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 8. Dynamic performance of the proposed Four quadrant converter at vs of 170 V

Fig. 9. Waveform and harmonics spectrum of 170V AC mains current (is) at full load

Fig. 10. Waveform and harmonics spectrum of 170V AC mains current (is) at Light load (10%)

260 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 8. Dynamic performance of the proposed Four quadrant converter at vs of 170 V

Fig. 9. Waveform and harmonics spectrum of 170V AC mains current (is) at full load

Fig. 10. Waveform and harmonics spectrum of 170V AC mains current (is) at Light load (10%)

261 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 11. Dynamic performance of the proposed four quadrant converter at vs of 270 V

Fig. 12. Waveform and harmonics spectrum of 270V AC mains current (is) at full load

Fig. 13. Waveform and harmonics spectrum of 270V AC mains current (is) at Light load (10%)

261 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 11. Dynamic performance of the proposed four quadrant converter at vs of 270 V

Fig. 12. Waveform and harmonics spectrum of 270V AC mains current (is) at full load

Fig. 13. Waveform and harmonics spectrum of 270V AC mains current (is) at Light load (10%)

261 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 11. Dynamic performance of the proposed four quadrant converter at vs of 270 V

Fig. 12. Waveform and harmonics spectrum of 270V AC mains current (is) at full load

Fig. 13. Waveform and harmonics spectrum of 270V AC mains current (is) at Light load (10%)

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June 2017

Experimental Results:Fig. 14 shows the experimental setup of the proposed four quadrant converter with welding load using adigital signal processor (DSP) TMS320F2812 for implementation of the control algorithm.

Fig. 14. Test setup of the proposed four quadrant converter with welding load

Fig. 15 shows the steady state performance result of the experimental setup under varying load whereas theDynamic performance results are demonstrated in Fig. 16. Harmonics spectrum of input AC mains current isshown in Fig. 17, for the proposed four quadrant converter operated at 10% and 100% loadings. Figs. 18-19present the waveforms of voltage and current along with performance values of power, energy and powerfactor under rated load conditions, which validates the achievement of desired objectives by the proposedconcepts.

262 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Experimental Results:Fig. 14 shows the experimental setup of the proposed four quadrant converter with welding load using adigital signal processor (DSP) TMS320F2812 for implementation of the control algorithm.

Fig. 14. Test setup of the proposed four quadrant converter with welding load

Fig. 15 shows the steady state performance result of the experimental setup under varying load whereas theDynamic performance results are demonstrated in Fig. 16. Harmonics spectrum of input AC mains current isshown in Fig. 17, for the proposed four quadrant converter operated at 10% and 100% loadings. Figs. 18-19present the waveforms of voltage and current along with performance values of power, energy and powerfactor under rated load conditions, which validates the achievement of desired objectives by the proposedconcepts.

262 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Experimental Results:Fig. 14 shows the experimental setup of the proposed four quadrant converter with welding load using adigital signal processor (DSP) TMS320F2812 for implementation of the control algorithm.

Fig. 14. Test setup of the proposed four quadrant converter with welding load

Fig. 15 shows the steady state performance result of the experimental setup under varying load whereas theDynamic performance results are demonstrated in Fig. 16. Harmonics spectrum of input AC mains current isshown in Fig. 17, for the proposed four quadrant converter operated at 10% and 100% loadings. Figs. 18-19present the waveforms of voltage and current along with performance values of power, energy and powerfactor under rated load conditions, which validates the achievement of desired objectives by the proposedconcepts.

263 Manoj Kumar and Sanjeev Singh

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ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 15(a)

Fig. 15(b)

263 Manoj Kumar and Sanjeev Singh

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June 2017

Fig. 15(a)

Fig. 15(b)

263 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

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June 2017

Fig. 15(a)

Fig. 15(b)

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June 2017

Fig. 15 (c)Fig. 15. Steady state performance of the proposed four quadrant converter at vs of 180 V fig. 15(a) to15(c)with power factor near to unity (0.98)

Fig. 16. Dynamic performance of the proposed four quadrant converter at vs of 220 V

264 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

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June 2017

Fig. 15 (c)Fig. 15. Steady state performance of the proposed four quadrant converter at vs of 180 V fig. 15(a) to15(c)with power factor near to unity (0.98)

Fig. 16. Dynamic performance of the proposed four quadrant converter at vs of 220 V

264 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

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June 2017

Fig. 15 (c)Fig. 15. Steady state performance of the proposed four quadrant converter at vs of 180 V fig. 15(a) to15(c)with power factor near to unity (0.98)

Fig. 16. Dynamic performance of the proposed four quadrant converter at vs of 220 V

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June 2017

Fig. 17 (a). Harmonics spectrum of the proposed four quadrant converter at vs of 220V AC mains current (is)at no load (10% load).

Fig. 17 (b). Harmonics spectrum of the proposed Four quadrant converter at vs of 220V AC mains current (is)at full load (100% load).

Fig. 18 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

265 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

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June 2017

Fig. 17 (a). Harmonics spectrum of the proposed four quadrant converter at vs of 220V AC mains current (is)at no load (10% load).

Fig. 17 (b). Harmonics spectrum of the proposed Four quadrant converter at vs of 220V AC mains current (is)at full load (100% load).

Fig. 18 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

265 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

Fig. 17 (a). Harmonics spectrum of the proposed four quadrant converter at vs of 220V AC mains current (is)at no load (10% load).

Fig. 17 (b). Harmonics spectrum of the proposed Four quadrant converter at vs of 220V AC mains current (is)at full load (100% load).

Fig. 18 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

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June 2017

Fig. 18 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 220V ACmains current (is) at full load (100% load).

Fig. 19 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

Fig. 19 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 245V ACmains current (is) at full load (100% load).

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June 2017

Fig. 18 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 220V ACmains current (is) at full load (100% load).

Fig. 19 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

Fig. 19 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 245V ACmains current (is) at full load (100% load).

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June 2017

Fig. 18 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 220V ACmains current (is) at full load (100% load).

Fig. 19 (a). Power and power factor of the proposed Four quadrant converter at vs of 220V AC mains current(is) at full load (100% load).

Fig. 19 (b). Input voltage and Current waveform of the proposed Four quadrant converter at vs of 245V ACmains current (is) at full load (100% load).

267 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

CONCLUSIONA regenerative AC-DC converter based welding power supply has been presented for improved power quality,light weight and efficient operation with excellent quality of welding results. An exhaustive performanceevaluation of proposed four quadrant converterfor welding application has been carried out under varyingloading and AC mains voltage conditions. From the presented performance results, it is concluded that theTHD of the input AC mains current remains within 5% for rated load as well as light load conditions in a widerange of operating AC mains voltage (i.e. from 170V to 270V). Fast dynamic response of proposed fourquadrant converterhas been achieved thereby improving the reliability of the system.

ACKNOWLEDGEMENTAuthors are thankful to NPIU, Noida and MHRD (Govt. of India), for providing financial support as a TEQIPgrant and also to SLIET Longowal through which this grant was sanctioned.

REFERENCES[1] Mohler. Rudy, “Practical welding Technology”, Industrial Press Inc., New York, 1983.[2] N. Mohan, T. Undeland and W. Robbins, Power Electronics: Converters, Applications and Design. Second Edition,

New York: John Wiley & Sons, 1995.[3] M. H. Rashid, “ Power Electronics Handbook”, Academic Press, 2007[4] Limits for Harmonic Current Emissions (Equipment input current ≤16 A per phase), International Standard IEC

61000-3-2, 2000.[5] Jeon S.J., Cho G.H., “Zero-voltage and zero-current switching full-bridge DC–DC converter for arc welding

machines,” Electron. Lett. 1999, 35, (13), pp. 1043–1044[6] John C. salmon, “circuit topologies for single phase- voltage-doubler boost rectifiers,” IEEE Trans. On Power

electronics, Vol. 8 no. 4, Oct 1993[7] B. Singh, BN Singh Ashish pandey, Kamal al- Haddad, A Review of Single-Phase Improved Power Quality AC-DC

Converters, ,” IEEE Trans., Ind. Electronics, vol. 50, no. 5, Oct 2003[8] Larry Jeffus, “Welding Principles and applications”, Fifth Edition, Delmar Learning, Inc., 2004.[9] J. R. Rodriguez, J. W. Dixon, J. R. Espinoza, J. Pontt and P. Lezana, "PWM regenerative rectifiers: state of the art,"

in IEEE Transactions on Industrial Electronics, vol. 52, no. 1, pp. 5-22, Feb. 2005[10]C. Klumpner, M. Corbridge, “A two-stage power converter for welding applications with increased efficiency and

reduced filtering,” in Proc. IEEE ISIE, 2008, pp. 251 – 256.[11]Maulik J. shah, U.A. Patel, R. P. Sadhu, M. N. Priyadarshi, “Design and simulation of 1 kW active rectifier,”

international conference on current trends in technology, ‘NuCONE-2010[12]Swati Narula, G.Bhuvaneswari,Bhim Singh, “Isolated Bridgeless Cuk Converter with Improved Power Quality for

Welding Power Supply” Asian Power Electronics Journal, Vol. 8, No. 2, Nov 2014

267 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

CONCLUSIONA regenerative AC-DC converter based welding power supply has been presented for improved power quality,light weight and efficient operation with excellent quality of welding results. An exhaustive performanceevaluation of proposed four quadrant converterfor welding application has been carried out under varyingloading and AC mains voltage conditions. From the presented performance results, it is concluded that theTHD of the input AC mains current remains within 5% for rated load as well as light load conditions in a widerange of operating AC mains voltage (i.e. from 170V to 270V). Fast dynamic response of proposed fourquadrant converterhas been achieved thereby improving the reliability of the system.

ACKNOWLEDGEMENTAuthors are thankful to NPIU, Noida and MHRD (Govt. of India), for providing financial support as a TEQIPgrant and also to SLIET Longowal through which this grant was sanctioned.

REFERENCES[1] Mohler. Rudy, “Practical welding Technology”, Industrial Press Inc., New York, 1983.[2] N. Mohan, T. Undeland and W. Robbins, Power Electronics: Converters, Applications and Design. Second Edition,

New York: John Wiley & Sons, 1995.[3] M. H. Rashid, “ Power Electronics Handbook”, Academic Press, 2007[4] Limits for Harmonic Current Emissions (Equipment input current ≤16 A per phase), International Standard IEC

61000-3-2, 2000.[5] Jeon S.J., Cho G.H., “Zero-voltage and zero-current switching full-bridge DC–DC converter for arc welding

machines,” Electron. Lett. 1999, 35, (13), pp. 1043–1044[6] John C. salmon, “circuit topologies for single phase- voltage-doubler boost rectifiers,” IEEE Trans. On Power

electronics, Vol. 8 no. 4, Oct 1993[7] B. Singh, BN Singh Ashish pandey, Kamal al- Haddad, A Review of Single-Phase Improved Power Quality AC-DC

Converters, ,” IEEE Trans., Ind. Electronics, vol. 50, no. 5, Oct 2003[8] Larry Jeffus, “Welding Principles and applications”, Fifth Edition, Delmar Learning, Inc., 2004.[9] J. R. Rodriguez, J. W. Dixon, J. R. Espinoza, J. Pontt and P. Lezana, "PWM regenerative rectifiers: state of the art,"

in IEEE Transactions on Industrial Electronics, vol. 52, no. 1, pp. 5-22, Feb. 2005[10]C. Klumpner, M. Corbridge, “A two-stage power converter for welding applications with increased efficiency and

reduced filtering,” in Proc. IEEE ISIE, 2008, pp. 251 – 256.[11]Maulik J. shah, U.A. Patel, R. P. Sadhu, M. N. Priyadarshi, “Design and simulation of 1 kW active rectifier,”

international conference on current trends in technology, ‘NuCONE-2010[12]Swati Narula, G.Bhuvaneswari,Bhim Singh, “Isolated Bridgeless Cuk Converter with Improved Power Quality for

Welding Power Supply” Asian Power Electronics Journal, Vol. 8, No. 2, Nov 2014

267 Manoj Kumar and Sanjeev Singh

International Journal of Electronics, Electrical and Computational SystemIJEECS

ISSN 2348-117XVolume 6, Issue 6

June 2017

CONCLUSIONA regenerative AC-DC converter based welding power supply has been presented for improved power quality,light weight and efficient operation with excellent quality of welding results. An exhaustive performanceevaluation of proposed four quadrant converterfor welding application has been carried out under varyingloading and AC mains voltage conditions. From the presented performance results, it is concluded that theTHD of the input AC mains current remains within 5% for rated load as well as light load conditions in a widerange of operating AC mains voltage (i.e. from 170V to 270V). Fast dynamic response of proposed fourquadrant converterhas been achieved thereby improving the reliability of the system.

ACKNOWLEDGEMENTAuthors are thankful to NPIU, Noida and MHRD (Govt. of India), for providing financial support as a TEQIPgrant and also to SLIET Longowal through which this grant was sanctioned.

REFERENCES[1] Mohler. Rudy, “Practical welding Technology”, Industrial Press Inc., New York, 1983.[2] N. Mohan, T. Undeland and W. Robbins, Power Electronics: Converters, Applications and Design. Second Edition,

New York: John Wiley & Sons, 1995.[3] M. H. Rashid, “ Power Electronics Handbook”, Academic Press, 2007[4] Limits for Harmonic Current Emissions (Equipment input current ≤16 A per phase), International Standard IEC

61000-3-2, 2000.[5] Jeon S.J., Cho G.H., “Zero-voltage and zero-current switching full-bridge DC–DC converter for arc welding

machines,” Electron. Lett. 1999, 35, (13), pp. 1043–1044[6] John C. salmon, “circuit topologies for single phase- voltage-doubler boost rectifiers,” IEEE Trans. On Power

electronics, Vol. 8 no. 4, Oct 1993[7] B. Singh, BN Singh Ashish pandey, Kamal al- Haddad, A Review of Single-Phase Improved Power Quality AC-DC

Converters, ,” IEEE Trans., Ind. Electronics, vol. 50, no. 5, Oct 2003[8] Larry Jeffus, “Welding Principles and applications”, Fifth Edition, Delmar Learning, Inc., 2004.[9] J. R. Rodriguez, J. W. Dixon, J. R. Espinoza, J. Pontt and P. Lezana, "PWM regenerative rectifiers: state of the art,"

in IEEE Transactions on Industrial Electronics, vol. 52, no. 1, pp. 5-22, Feb. 2005[10]C. Klumpner, M. Corbridge, “A two-stage power converter for welding applications with increased efficiency and

reduced filtering,” in Proc. IEEE ISIE, 2008, pp. 251 – 256.[11]Maulik J. shah, U.A. Patel, R. P. Sadhu, M. N. Priyadarshi, “Design and simulation of 1 kW active rectifier,”

international conference on current trends in technology, ‘NuCONE-2010[12]Swati Narula, G.Bhuvaneswari,Bhim Singh, “Isolated Bridgeless Cuk Converter with Improved Power Quality for

Welding Power Supply” Asian Power Electronics Journal, Vol. 8, No. 2, Nov 2014