ENERGY SAVING DEVICE FOR WELDING

TRANSFORMER
Submitted for the partial fulfillment of requirement for the degree of
BACHELOR OF ENGINEERING
(Electrical & Electronics Engineering)

Submitted by:- Guided by:-

Mr. Shubham R. Jaiswal Prof. K.S.Kalkonde

PROF. RAM MEGHE COLLEGE OF ENGINEERING &

MANAGEMENT, BADNERA.
CONTENTS
INTRODUCTION
IMPORTANCE OF ENERGY SAVING
TYPES OF POWER SOURCES FOR WELDING
WELDING TRANSFORMER
FACTOR SELECTION FOR POWER SOURCES
POWER LOSSES (CAUSE & REMEDIES)
BLOCK DIAGRAM OF “ESD”
OPERATION OF “ESD”
SALIENT FEATURES OF “ESD”
FUTURE SCOPE
CONCLUSION
REFERENCES
 INTRODUCTION
 The welding machines are extensively used in different sectors such as
railways, large scales fabrications, heavy industries etc. and there are
about 95 % of industries which directly or indirectly use welding
machines.

 Welding machine require high amount of power ranging in kilowatts to

megawatts. This also accounts for heavy power wastage in the form of no
load loss, which by effective designing can be reduced to a considerable
level and this will not affect the welding performance of the equipment,
by reducing the no load loss in welding transformer we can very
effectively reduce the overall cost of machines.

 There are about 50 lakh welding machines connected to the supplies out
of which at least about 7.5 lakh machines are always in operation round
the clock.
 WHY “ENERGY SAVING ???”

 Saving energy means wasting less money.

 Saving energy means wasting less primary fuel (coal, gas, oil, uranium).

 Saving energy means producing less pollution.

 If we succeed in saving the extra power wasted then it will definitely be a

great help to the nation as well as the individual. The same power save can
be effectively use in operating some other equipment at practically no
extra cost of generation.
POWER SOURCES
 To supply the electrical energy necessary for arc welding processes, a
number of different power supplies can be used.

 Following are basic feature of the arc welding power source:

1.Static characteristic curves (volt – amp )

2. Open circuit voltage (OCV)
3. Static and dynamic characteristics
4. Current rating and duty cycle specification
5. Classes of insulation
6. Power factor
WELDING TRANSFORMER

 It is a step down transformer that converts mains voltage and

current to a sufficiently high current at the output such as is
essential for generating the arc necessary for welding. It involves
no moving parts. Simply put, It is a transformer used in electric arc
welding.
FACTOR SELECTION FOR POWER SOURCES

The following factor must be considered in choosing a power source from

among a transformer, generator and rectifier:
 Initial cost.

 Power factor of machine.

 Whether the welding job required AC or DC both AC and DC.

 Whether the machine has adequate current rating and range to weld
with the largest and smallest size of electrodes to be used on the job.

 Whether remote current control arrangement will help and whether

machine can provide it.
 POWER LOSSES
 The no load current of the transformer consists of two component:

1) The magnetizing component, which is in phase with the magnetic flux.

2) The core loss component, which is opposite in phase with the induced
E.M.F.
BLOCK DIAGRAM OF “ESD”
OPERATION OF “ESD”
 FIRST STAGE:-

Initial on Condition

 SECOND STAGE:-

PHASE 1

 THIRD STAGE:-

PHASE 2
FEATURES
 Salient features of the circuit are as follows:

1) This circuit operates both on AC as well as on DC welding machine.

2) This circuit is highly reliable in operation as it is very simple circuit due

to use of controller and relays.

3) The sensing of different voltage condition is not problem as we are

sensing voltage level and not particular voltage magnitude.

4) This circuit operates on 12 volt as well as 5volt DC supply. Due to this

power loss is less.
 FUTURE SCOPE
 The above described circuit can be taken as a stepping stone in the field of
energy saving. Other circuit can be design on similar pattern which can be
very effective for saving power in different equipment.

 This particular circuit is built in such a way that the operator training is not
necessary and hence can be adopted equally by both rural and urban
consumers.

 The energy saving is demand of present time and hence always

appreciable and acceptable by all.

 It helps in saving a lot of national wealth in term of power and also useful
to solve load Shedding problem if use extensively.
.
CONCLUSION
At no load by using conventional method the machine is continuously
ON therefore no load power losses is 10% to 15% of its rating. By using
energy saving device the No load losses are zero.
REFERENCES

 A project report on ESD

-by Prof.Dr.GOKHALE

 Welding power handbook

-by A.F.MANZ.

 Welding handbook
-by AMERICAN WELDING SOCIETY

 A Book of welding technology

-by Prof.NADKARNI

 Workshop technology (volume1)

-by HAJARQ CHAUDHARY