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Welding Inverter


Welding inverters are one of the major sources of power supply needed for resistance welding. Though there are other options, like, transformers and rectifiers; however, a welding inverter has their own advantages over the other power supply equipment.

Function of welding inverters

The function of a welding inverter is used as the power supply sources in welding shops.

Initially, AC line voltage is taken as the input to the welding equipment, and is suitably RFI/EMI filtered and rectified. The rectified voltage is filtered to make it pure DC, and then a high frequency power transformer is used to take this DC voltage, as the input, to the switching device. However, the size of the transformer becomes very small, due to the very high switching frequency. Then the output of the transformer is stepped down suitably, and the stepped down AC voltage is rectified again with the help of fast recovery diodes, which is then used for welding. The main advantages of these welding inverters as can be seen from here is that they provide excellent torch ignition and also various types of outputs to the welding processes.

Some of the situations where a welding inverter can be of real help in the welding shop:

" Welding inverters are helpful when you have to weld the parts that are difficult to move to the work site
" When bringing a larger welder close to the job site while working in tight spaces is not possible.
" Problem with primary power supply, or difficulty in finding usable primary power supply.

Advantages of Welding Inverters

Though welding inverters are not used as primary sources of power supply in welding shops, still they have wide variety of advantages. Some of them are given below:

Multiple process welding outputs

Different models are available for Stick/DC, TIG, and DC TIG/Stick; have more functions for controlling the TIG arc; AC/DC TIG/Stick or a CC/CV output. A CC/CV inverter can be considered as one less machine to purchase or transport to the job site.

Dig control for Stick welding

" To save the electrodes due to the shortness of the arc, Dig control is used.
" Broad range of inductance control for MIG welding is available.
" It helps in creating a softer or stiffer arc, and add more inductance for better wet-out.

Excellent arc starts

As the arc fails to establish itself quickly, weld flaws often occur during its starting periods. And this is where the importance of welding inverters come into fore: these welding inverters provide more positive arc starting, which helps in ensuring a quality weld the first time and no reworking is required thereafter.

Improved pulsed MIG or TIG output

Pulsing can reduce heat input for less warping distortion, improve bead aesthetics, reduce spatter, provide out-of-position puddle control, and increase travel speed; however, all this depends upon the application. Here a Welding inverter is of real help for this feature.

Output frequency adjustment and extended balance control for AC TIG welding

Weld bead profile is tailored by these features so as to improve weld quality; minimize post-weld grinding; and substantially increase travel speed, which makes welding inverters very suitable for these applications.

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