Power quality improvements of arc welding power supplies by modified bridgeless SEPIC PFC converter
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ORIGINAL ARTICLE
Power quality improvements of arc welding power supplies by modified bridgeless SEPIC PFC converter Amar Bouafassa1 · Luis M. Fernández‑Ramírez2 · Badreddine Babes3 Received: 19 December 2019 / Revised: 19 August 2020 / Accepted: 31 August 2020 © The Korean Institute of Power Electronics 2020
Abstract This paper proposes an efficient bridgeless power factor corrected (PFC) modified single ended primary inductor converter (SEPIC) for arc welding power supplies (AWPS). The overall configuration is composed of two converters: (1) a modified bridgeless SEPIC PFC converter, which is controlled by a PI controller to achieve a high power factor and fast response; and (2) a full bridge buck converter with high-frequency transformer for high-frequency isolation to ensure arc welding stability. The proposed system is simulated under different operating conditions of an AWPS. It is also tested in real time by a hardware-in-the-loop system based on a dSPACE DS1103 control board. The system performances are evaluated based on power quality indices such as power factor, total harmonic distortions of the AC grid current, and voltage regulation. The obtained results show that the proposed controller enhances the weld bead quality by keeping a constant current at the output and a stable arc, meet the international power quality standards and robustness for voltage regulation. Keywords Arc welding power supply · Bridgeless PFC converter · Modified single ended primary inductor converter · PI controller
1 Introduction Joining metals have become a fundamental issue in modern industrialized operations. It can be accomplished through different welding processes such as gas welding, resistance welding, arc welding, and so on. Among all these kinds of welding processes, more attention and popularity has been focused on arc welding due to its flexible automation and high efficiency [1, 2]. Due to the excessive heat from electrode wire, important challenges in the development of an arc welding power supply are the control of the feed-rate of the electrode and * Amar Bouafassa [email protected] 1
Department of Electronics, Electrical Engineering and Automation, National Polytechnic School of Constantine, Constantine, Algeria
2
Research Group in Sustainable and Renewable Electrical Technologies, Department of Electrical Engineering, Higher Polytechnic School of Algeciras, University of Cadiz, Cadiz, Spain
3
Research Center in Industrial Technologies (CRTI), Algiers, Algeria
maintenance of the arc stability since a small arc length variation can induce enormous arc voltage fluctuations that may exceed the maximum allowable range of the power supply. For these reasons, the welding load current must be controlled and limited during overload conditions. The aim of the proposed controller for AWPS is to provide perfect dynamic responses through the regulation of the output voltage and the output current. A single-phase full bridge buck converter connected at the point of common coupling (PCC) with an un
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