XIII International PhD Workshop OWD 2011, 2225 October 2011

Iron Core Power Losses of an Medium Frequency Resistance Spot Welding Transformer

Martin Petrun, University of Maribor (prof. dr. Drago Dolinar, University of Maribor)
A stract

This paper deals with power losses in a laminated magnetic core of a medium frequency resistance spot welding transformer (RS T). The aim of this wor! is to e"aluate the iron core power losses of an RS T for iron cores with different lamination thic!ness and for different operating temperatures. This e"aluation is used for the ad"anced design of RS Ts. #or determination of iron core losses a la$oratory measuring system is used. #urther, an e%perimental method for separation of iron core losses is presented. The proposed method separates iron core losses into two components& hysteresis losses and dynamic losses. The results are "alidated with a dynamic model of the RS T iron core.
!" Introduction

$ut it can significantly increase the temperature of the transformer and decrease the efficiency. -n RS T transformers, ',type iron cores are used (#ig. )), where A#e is the effecti"e area of the iron core cross section, is the air gap length, b is the lamination thic!ness, a, c, e, g are the iron core dimensions. This type of iron cores are used mainly $ecause of the easier assem$ling of the transformers. ith the adequate selection of the iron core for the RS T, the losses in the spot welding system can $e reduced and the efficiency can $e increased.

AFe e
a

The resistance spot welding systems are mainly used for ine%pensi"e and relia$le welding of car $odies in the automoti"e industry. Required compact construction and e%tremely high dynamics of the welding current can $e achie"ed with a medium frequency resistance spot welding system with D' welding current ()*. Such system typically consists of an input +,$ridge in"erter, welding transformer, and a full,wa"e output rectifier mounted on the transformer. Due to the e%tremely high power losses, the transformer is water cooled. The portion of power losses in the transformer is indeed not compara$le to power losses of the output rectifier,

b g c

Fig.1. Iron cor e of t he RSWT.

#" Met$ods of Analysis

#"! %&perimental Setup and Measurements

The applied e%perimental setup consists of +, $ridge in"erter for generation of the square wa"e supply "oltage, tested RS T and measuring equipment (#ig. .).

Fig.2. Schematic presentation of the measurement system.

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/ set of measurements is performed for different amplitudes of the supply "oltage UD' ()). The "oltage UD' is set with the autotransformer. The frequency f is set for each test indi"idually according to (.), where A#e is the effecti"e area of the iron core cross section and Np is the num$er of turns of the primary winding.
U DC = AFe N p dB dt

PFe = C h B max

dB dB + Ce dt dt

+ C exc

dB dt

(3)

()) (.)

f =

U DC 4 Bmax AFe N p

PFe/dB/dt

-n such way, the predefined "alues for the time deri"ati"e of the a"erage magnetic flu% density 0dB/dt0 and for the ma%imal magnetic flu% density Bma% are set. /ll tests are performed for no,load operation, throughout the operation range 120dB/dt02)3111 T4s and 12B2).3 T. 5ote that nowadays medium frequency RS Ts operate appro%imately at ) !+6 with the UD' around 711 8. The nominal operating range is typically $etween the saturation points of the magneti6ation characteristic. -n order to pre"ent the iron core saturation, different approaches are used (.*. The total a"erage iron core losses P#e are determined from the measured supply "oltage u(t) and responding current i(t) $y numerical integration of the instantaneous power (9), where T! is the time of the measurement.
PFe = 1 Tk
Tk

where Ch, Ce and Cexc are the loss component coefficients, e%ponents and depend on material properties, material treatment, etc. and can "ary from one to three, $ut are often chosen as ;. and ;),3 (3*. The proposed e%perimental method is $ased on (3), where the hysteresis loss component has linear relation to the change of the magneti6ation rate, while the other two components are affected differently. +ence the factors and are not e%actly !nown, it is difficult to separate the losses into three components (:*. The total magnetic core power losses are separated into the hysteresis component Ph and dynamic component Pdyn according to #ig. 9. /n e%trapolation of the o$tained results has to $e performed, $ecause measurements for "ery low "alues of dB4dt are usually not feasi$le. The e%perimental method is also "erified with a dynamic model of the iron core of an RS T (9*.
0.05 0.04 0.03 0.02 0.01 0
Ph /dB/ dt

extrapolated measured

(u i ) d t
11 0

(9)

Pdyn/dB/dt

The copper loss and lea!age field can $e neglected due to the low ohmic resistance and lea!age field of primary winding and no,load operation (9*. +owe"er, more accurate results can $e achie"ed with the measuring of the induced emf in the additional secondary winding.
#"! %&perimental Separation of Iron Core Power Losses

2000

4000 dB/ dt

6000

8000

Fig.3. Graphical presen tation of th e proposed met hod.

'" Results

Traditionally, the a"erage iron core losses P#e are separated into three empirical components (:*. These components are the hysteresis loss Ph, eddy,current loss Pe and e%cess loss Pe%c (:). The eddy,current and e%cess losses are generally denoted as the dynamic losses Pdyn, as they depend nonlinear on the rate of the magneti6ation change.
PFe = Ph + Pe + Pexc = Ph + Pdyn

(:)

The traditional loss components are often descri$ed $y (.)

RS Ts analy6ed in this paper are la$oratory transformers samples with different lamination thic!ness. Results are shown for two Trafoperm 5. (3* iron cores with lamination thic!ness b of 1.) mm and 1..< mm. 8oltages and currents ha"e $een captured at the RS T primary terminals $y a digital control system dSP/'= DS))19PP'. The sampling frequency has $een set to achie"e )11 samples per cycle of the e%citation "oltage. /n e%ample of the o$tained wa"eforms is shown in #ig. :.

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200 100 u [V] 0 -100

b =0.27 mm

250 200
PFe [W]
300 300.5 301 301.5 302 302.5 303 303.5

approximated surface measurements 250 200

PFe [W]

b =0.1 mm

-200

150 100 50 0 4000 2000 1 0.5 0 0

Bmax [T]

150 100 50 0

0.5 0.25 i [A] 0 -0.25 -0.5 300 300.5 301 301.5 302 302.5 303 303.5

1.5

4000 2000 dB/dt [T/s] 0 0 1 0.5

Bmax [T]

1.5

dB/dt [T/s]

0.5 B [T] 0.25 0 -0.25 -0.5 300 300.5 301 301.5 t [ms] 302 302.5 303 303.5

Fig.'. *easur ed and appro"imated iro n core loss es o$er th e #ide operating rang e.

'"! Loss Separation

oltage! curr en t and fl u" densit y #a$efo rms during the tes t for 1%%% T&s and %.' T.

Fig.4.

The comparison of the iron core losses with the lamination thic!ness 1,)mm and 1,.<mm is shown in #ig. 3. The results are for different ma%imal flu% densities Bma% in the iron cores.
350
Bm=0,8 T

The e%perimental iron core loss separation o"er the wide operation range is shown in #ig. >. The results show that are the hysteresis losses lower in the iron core with thic!er lamination. That has $een "erified with an independent measurement of the static hysteresis for $oth cores (#ig. <). #or this measurement an e%perimental method has $een used (7*.
2
b=0,27mm b=0,1mm

300 250
P PFe Fe [W]

Bm=0,6 T Bm=0,4 T

b=0,3 mm

1.5 1

200
B [T]

0.5

150 100 50 0 0 2 4 6

b=0,1 mm
0 -0.5 -1 -1.5

dB kT dt s

10
-2 -150 -100 -50 0 H [A/m] 50 100 150

Fig.(. )omparison of t#o diff er ent iro n cores . Fig.+. *easur ed static h yster sis.

The losses in the iron core with the thic!er lamination are much higher, due to the eddy currents. The eddy,currents are much more present in the iron core with the thic!er laminations, as shown $elow with the proposed e%perimental method for loss separation (#ig <). The measured iron core losses P#e o"er the wide operation range are shown in #ig. 7. /n appro%imation of the o$tained characteristic is performed to o$tain a smooth surface. Moreo"er, in the area Bma% 2 1.9 T and high deri"ati"e 0dB/dt0, an e%trapolation of measured results is carried out. Measurements for this area are namely not feasi$le, $ecause e%tremely low amplitudes of UD' and high frequencies f of the e%citation "oltage are required. The appro%imation and e%trapolation is needed for separation of the iron core losses into the hysteresis and dynamic component

The hysteresis of the thic!er iron core is much more narrow than the hysteresis of the thinner lamination. ?n the other hand, the dynamic losses in the thic!er lamination much higher due to the higher eddy,currents.
b =0.27 mm b =0.1 mm

80
Ph [W]

80
Ph [W]

60 40 20

60 40 20

0 5000 0.5 1

1.5 0 0
Bmax [T]

0 5000 0.5 1

1.5 0 0
Bmax [T] b =0.1 mm

dB/dt [T/s]
b =0.27 mm

dB/dt [T/s]

200
Pdyn [W] Pdyn [W]

200

100

100

0 5000 0 0 0.5 1

1.5

0 5000 0 0 0.5 1

1.5

dB/dt [T/s]

Bmax [T]

dB/dt [T/s]

Bmax [T]

Fig.,. The h yst eresis and dyn amic loss component s - h and - d y n separated #ith t he p roposed method.

336

'"# T$e impact of t$e operating temperature

The RS Ts are wor!ing on high temperatures that are reaching up to ).1@'. This is $ecause of the high power losses in the spot welding system. Therefore additional measurements are performed, where the iron cores are heated to A1@' to see if the temperature of the iron core influences the power losses in the iron core. Benerally the eddy,currents should $e lower due to the higher conducti"ity of the lamination sheets. Cut the results are showing, that this influence is negligi$le (#ig. A).
150
PFe [W] B0=0,8 T

(9*

(:*

250 200
PFe [W]

B0=0,8 T

(3* (7*

100 50 0

150 100 50

2000

4000

6000

dB T dt s

2000

dB T dt s

4000

6000

'on"erters,G !### Trans$ Magn$" "ol. :7, no. ., pp. 3>.,>3>, .1)1. 8. Podlogar, C. IlopJiJ, B. Htum$erger and D. Dolinar, FMagnetic 'ore Model of a Midfrequency Resistance Spot elding Transformer,G in !### Trans$ Magn$" "ol. :7, no. ., pp. 71.,713, .1)1. =. Dlala, F'omparison of Models for =stimating Magnetic 'ore Dosses in =lectrical Machines Lsing the #inite,=lement Method,G !### Trans$ Magn$, "ol. :3, no. ., pp. <)7 , <.3, .11A. R. Coll, Weich%agnetische Wer&stoffe" :. /uflage., 8acuumschmel6e Bm$+, +anau )AA1. B. Htum$erger, C. PolaEKer, C. Htum$erger, M. Toman, and D. Dolinar, F="aluation of =%perimental Methods for Determining the Magnetically 5onlinear 'haracteristics of =lectromagnetic De"ices,G !### Trans$ Magn$" "ol. :), no. )1, pp. :191 , :19., ?ct. .113.

Fig... Iron cor e losses fo r diff er ent t empera tur es fo r iron core #ith / 0%!2 +mm.

Aut$or*

(" Conclusion

This paper presents an e%perimental procedure for determination and e"aluation of iron cores for RS Ts. Cased on the test results o$tained for different la$oratory RS Ts (lamination thic!ness 1.) mm and 1..< mm), it can $e concluded that the magnetic core loss components $eha"e as e%pected. -t is also shown that the operating temperature of the spot welding system does not change the power losses in the iron core. /n e%perimental method for separation of magnetic core power losses into two components& hysteresis losses Ph and dynamic losses Pdyn, is also proposed. The results are "alidated with a dynamic model. The presented e%perimental method gi"es a good estimation of the magnetic core loss components and can $e used for determination of the quality of the iron core material and construction for the RS Ts. -n this way, the $est iron cores for RS Ts can $e chosen. The implementation of the proposed e%perimental method is rather simple, which gi"es a possi$ility to apply it on other electromagnetic de"ices.
)i liograp$y

Martin Petrun Lni"ersity of Mari$or, #=RSmetano"a )< .111 Mari$or Slo"enia tel. M9>7 . ..1 <1:7 emailN %artin$'etrun(uni)%b$si

. Di, =. #eng, D. 'erEanec, and B. /. Br6a6ins!i, F=nergy 'onsumption in /' and M#D' Resistance Spot elding,G Sheet Metal Welding Conference !" Sterling +eights, M-, May .11:. (.* B. Htum$erger, C. IlopJiJ, I. DeKela!, D. Dolinar, FPre"ention of -ron 'ore Saturation in Multi, inding Transformers for D',D'

()*

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