DC arc welding power rectifier systems typically utilize a secondary winding of each main transformer that is isolated, with unregulated semiconductor rectifier elements placed outside the desired characteristics. This configuration allows for the creation of a pointing device-like structure, which can be used in conjunction with electrodes to perform manual arc welding.
The most commonly used arc welding rectifiers are categorized into four types based on their adjustment mechanisms: movable-iron type, moving-coil type, magnetic amplifier type, and thyristor type. The movable-iron rectifier operates on a principle similar to the iron-core type arc welding transformer. In this system, the transformer produces an alternating current (AC) output, which is then converted to direct current (DC) using silicon diodes. A reactor is used to filter the DC output, ensuring a stable and smooth current for welding applications.
A dynamic welding rectifier often uses a bridge rectifier configuration, typically composed of three or more components. These devices are designed to provide consistent and controlled output for various welding tasks.
Magnetic amplifier arc welding rectifiers come in three configurations: internal feedback, no feedback, and external feedback. These systems regulate the current to achieve the desired output characteristics. However, due to their high energy consumption, complex manufacturing process, and reliance on consumables, magnetic amplifiers have largely been replaced by more advanced electronic solutions as the electronics industry has evolved.
Thyristor-based arc welding rectifiers offer excellent controllability. By adjusting the conduction angle of the thyristor, the shape of the external characteristic curve and the welding parameters can be precisely controlled. This makes them highly versatile and suitable for a wide range of welding applications.
The basic structure of a thyristor arc welding rectifier includes a transformer (B), a thyristor rectifier group (SCR), and an output reactor (DK). The triggering mechanism consists of a trigger circuit (C) and a synchronization circuit (T). When a drooping external characteristic is required, the phase of the trigger pulse is determined by the reference voltage (Ugi) and the current feedback signal (Ufi). For a flat external characteristic, the trigger pulse phase is set by the reference voltage (Ugu) and the voltage feedback signal (Ufu). This ensures accurate control over the welding output, enhancing both performance and reliability.
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