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DESIGN AND CONSTRUCTION OF A WELDING

MACHINE WITH A VARIABLE CURRENT
SELECTOR

Article · February 2016

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International Journal of Pure & Applied Sciences Vol.6No.2.
Published by Oxford Research and Publications January,2016

DESIGN AND CONSTRUCTION OF A WELDING MACHINE WITH A VARIABLE

CURRENT SELECTOR
1*
I. I.Ibrahim and 2B. I. Adamu
1&2
Department of Physics, Federal University, Dutse, Jigawa State
Corresponding author email: idowuaraba@gmail.com,
+2348036826053
Abstract
A two pole type of an a.c variable current welding machine was designed and constructed. The
first pole is the primary circuit and was design to have a four step coil SA, AB, BC and CE with
three looping A, B, C for the variable selection of current capacity. The primary circuits was
coiled with a copper wire of size gauge 13 and were given turns of 80, 20, 20 and 20 turn for
step SA,AB, BC and CD respectively. The second pole is the secondary circuit side which was
design to have both primary circuit and the secondary circuit lapping on each other. The
primary circuit on the secondary pole was wound with copper wire of size gauge 13 and was
given one step winding turn of 114 turns while the lapped secondary circuit was given one step
turn of 40 turns with a tick copper wire of size gauge 8. The start to start connection style was
use for the primary circuits while the secondary circuit starts and end hands were connected to
the earth and tong of the welding machine respectively.
Keywords: Secondary circuit, primary circuit, coil, welding
1.0 INTRODUCTION
Welding is a fabrication process that joins materials usually metals or thermoplastics, by
causing coalescence. Generally, most of the weldable common steels are preferred to be
join by welding method.[1] The most popular of the welding machines uses the arc
welding methods, which include the (i) SMAW – The stick welding or shielded metal arc
welding (ii) GMAM – The tig welding gas metal arc welding (iii) GTAM – The tig
welding or gas tungsten arc welding[2]. Others are brazing, soldering and oxyacetylene
welding. In the automobile industry the resistance spot welding (RSM) is one of the most
efficient material-joining processes, it utilizes currents in the range of 1 – 200KA with
durations ranging from a few cycles to one second to generate joule heating. RSM
transformers operates within a middle frequency range of around 1kHz[3].
In this research the welding system constructed uses low frequency transformer that
operate at the utility mains frequency of 50 or 60 Hz with variable current selectors to
avoid power quality problem. Power quality problem refers to voltage current and
frequency deviation from nominal value in electrical distribution and utilization system.

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International Journal of Pure & Applied Sciences Vol.6No.2.
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Any significant deviation in the waveform magnitude, frequency or purity is a potential

power quality problem which may result in failure or malfunctioning of equipment [2].
The current selector introduced in this transformer help to maximize the power quality
problem association with a.c electric power systems, that operates at a sinusoidal
waveform of 50 or 60 Hz and rated voltage magnitude. The deviations depends on the
duration and magnitude which help to categorize the voltage deviation as voltage sags,
interruption, over voltage, under voltage, transients, voltage imbalance and voltage
flickering[4,5]. In many electric welding systems, a potential difference of 50-70 volts is
required to strike an electric arc. After the arc is struck, an essentially constant current
supply is desired .The welding transformer converts the high voltage and low
current from the utility mains into low voltage and high current, usually in the
range of 55 – 590 amperes [6, 7]. In this transformer the variable current selector
help to maintain the constant current supply desired.
2.0 DESIGN PROCEDURE AND ANALYSIS
The a.c welding machine design is a two pole circuit, with the first pole been the
primary circuit and the second pole is the secondary circuit.
2.1 The Primary Circuit (pole 1)
The primary circuit was design to vary in current selection without tempering with the
coil itself; it has a four step coil with three looping for the selection of current capacity.

Fig 1: A circuit showing the four step circuit and the looping for the current selection

In the primary circuit the winding begins at the start point S and was given 80 turns with
a copper wire of size gauge 13. The first looping was introduced after the first winding
and was labeled A, the winding continues with same size gauge for another 20 turns

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International Journal of Pure & Applied Sciences Vol.6No.2.
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before the second looping labeled B. The third looping C and the last winding labeled E
was given 20 turns each with same size wire gauge 13. The beginning of the wire marks
the starting point „ S‟ and the end of the wire marks the ending point „ E‟, both point are
use for connection purposes.
2.2 The Secondary Circuit (Pole 2)
The second circuit was design to consist of two coils over lapping each other. The first
coil is the primary coil wound with 114 turn‟s size wire gauge 13 while the secondary
coil was 40 turn of tick size wire gauge 8 as shown in figure 2. The starting point and
ending point of the secondary coil serve as the welding terminals.

Fig 2 : A circuit showing the secondary circuit with the over lapped primary circuit
3.0 INSTRUMENTATION
The instruments involved for the design are (1) the core (2) copper wire as my soil (3)
insulators for separations.
3.1 The Core
The core is made of laminations assembled to provide a continuous magnetic path with a
minimum of air gap included. The lamination steel help to minimize eddy current loss
and the thickness of the lamination varies from 0.35mm for a frequency of 50Hz
0.5mm for a frequency of 25Hz[8]. The cores are cut in the form of long strips. L‟s, E‟s
and I‟ shapes as shown below.

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International Journal of Pure & Applied Sciences Vol.6No.2.
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Fig 3: Diagrams showing the shapes of a laminations

Laminated Core

Coils

Butt Join
Fig 4: Diagrams showing the arrangement of a laminated core on the coil
In other to avoid reluctance at the joins where the laminated cores are butted against each
other, the alternate layers are stacked differently with the shape I to eliminated joins as
shown below.

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International Journal of Pure & Applied Sciences Vol.6No.2.
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Close Gap Butt Joint

Fig 5: Diagrams showing the arrangement of the I lamination covering the butted joint
3.2 Copper as my coil
Copper wire is of more advantage in winding process than that of aluminum. Copper wire
has more capacity and strong enough to resist the function of any kind of winding for a
longer time. It has different type of gauge and is coated with insulator to prevent contact
of wires when winding.
For the aluminum wire its very effective when used than the copper wire, it produces
stronger magnetic flux which makes the machine more powerful. The disadvantage of an
aluminum wire is that they are not insulated thereby need proper insulation before it can
be used for winding.
3.3 Insulators
Insulators are materials that do not conduct electricity in any form. They are used to
separate two wires to avoid partial contact of any form.
4.0 CONSTRUCTION, CONNECTIONS AND TESTING
4.1 Construction
In the construction, the laminated core was arranged first to form the two poles as shown
below

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International Journal of Pure & Applied Sciences Vol.6No.2.
Published by Oxford Research and Publications January,2016

Fig 6: Diagrams showing the formation of the two poles laminated stand

The total laminated core used for the I stand pole was 480 and that of L shape was a total
of 480, given and a net total of 960 laminated core used in all.
In the winding, the shape of the laminated core was taken and a core was form for the
winding of the coil as shown in figure 7

Fig 7: A Diagram showing the coil and the winding shape with respect to the laminated
core

The next step was the fixing of the coil in the pole and the crossing of the top of the
machine with an „I‟laminated core to avoid Butt joint. The complete construction work is
as shown in the figure below.

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International Journal of Pure & Applied Sciences Vol.6No.2.
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Fig 8: A Diagram showing the complete coupled construction work of the welding
machine

4.2 Connections
The major kinds of connections that can be given to this construction include:
a) Star-delta connection or End to start connection
b) Star – star connection or start to start connection
c) Delta-Delta connection or End to End connection
The type of connection use in this work is the start to start connection; it involves the
starting wire hand of the primary circuit connected to the secondary circuit as shown in
figure below.

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International Journal of Pure & Applied Sciences Vol.6No.2.
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Fig 9: A circuit diagram showing the detail connection of the primary circuits

Owing to the connection between the primary pole and the secondary pole, the primary
turns will toggle with respect to the variation of the current thus, 254 turns from S to A,
174 turn from A to B, 154 turns from B to C and 114 turns from C to E.
At the secondary circuit, the starting hand is connected to the earth of the welding side
and the end hand connected to the tong bearing the electrode.
4.3 Testing
The testing of the machine confirmed the success of the design, construction and
connection of the work, as there was no spark or shock from the laminated core and when
connected to the welding apparatus, it was used for joining metals without any problem.

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International Journal of Pure & Applied Sciences Vol.6No.2.
Published by Oxford Research and Publications January,2016

In the testing, the voltages at zero load and when in operation was measured and recorded
as shown in the result below.

5.0 RESULT AND DISCUSSION

5.1 Result
Being a variable transformer selection type, the current at both input and output of the
transformer were determined thus;
Table 1: showing the input and output voltage values from the welding machine
Terminals Pri turn Sec. turn Vin Vout Scaling Factor Turn factor
(NP) (Ns) (V) (V) Vout/Vin Ns/Np
A 254 40 240 37 37/240 = 0.154 40/254 = 0.157
B 174 40 240 41 41/240= 0.171 40/174 = 0.230
C 154 40 240 45 45/240 = 0.190 40/154 = 0.260
D 114 40 240 50 50/240 = 0.208 40/114 = 0.351

The voltage in (Vin) was determined directly from the mains of power supply and
recorded. The voltage out (Vout) was recorded when the transformer was connected to the
power supply at zero load while the scaling factor is the ratio of the output voltage and
input voltage. The turn factor was also calculated to determine the relationship of the turn
given to the transformer and the scaling factor as shown above.
5.2 Discussion
The result shows that the scaling factor and the calculated turn factor differ with the
range of 0.275 which dictates the transformer losses during operation. These losses range
from eddy current losses, winding resistance losses, hysteresis losses and mechanical
losses.
It was also observed that the scaling factor and the turn factor at terminal A is almost the
same, this shows that the higher the turns the better the transformer to avoid high current
which may cause spark and may consequently lead to fire outbreak.
The determination of the various input and output current enable the user to vary the `
Current in supply and also use the appropriate volts for the welding desire.

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 International Journal of Pure & Applied Sciences Vol.6No.2.
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6.0 CONCLUSIONS:
In the use of welding machine the challenges observed is the power quality problems and
the leakage of a welding transformer. This paper was to design and construct a welding
machine that can essentially maintain the constant current supply desired to check or
solve the power quality problems associated with the welding process and to improve on
the leakage through the turn ratio given to the transformer. In the course of the
construction the role of the turns given to a transformer was fascinating, as it shows that
the higher the turns, the more efficient the transformer as stated in the discussion above.

REFERENCES
[1] S. Catarina, “Finite element analysis of a welding transformer,” vol. 18, no. March, pp.
212–221, 2014.

[2] M.Mengesha and M.Adefris, “Power Quality Assessment And Mitigation At Walya-Steel
Industries And Ethio-Plastic Share Company,” vol. 31, no. 2014, pp. 10–17, 2014.

[3] V. Podlogar, B. Klopcic, G. Stumberger, and D. Dolinar, “Magnetic core model of a

midfrequency resistance spot welding transformer”, IEEE Trans. on Magnetics,doi:
10.1109/TMAG.2009.2031979

[4] Angelo Baggini “Hand book of Power Quality”,John Wiely & Son Ltd, 2008

[5] Rogger G.Dugan, F.McGrangana “Electrical Power quality System”, 2nd edition, McGraw-
Hill, 2004.
[6] G.R. Slemon and A. Straughen, Electric machines (Addison Wesley Publishing Company,
London, 1982), pp. 172.

[7] B. Klopcic, D. Dolinar and G. Stumberger, “Advanced control of a resistance spot welding
system”, IEEE Trans. on Power Electronics, doi: 10.1109/TPEL.2007.911851

[8] Q. I. U. Qi, L. I. Xigong, Z. Zhaofeng, and S. Wei, “The Development Of A 20 Khz High-
Power Inverter Spot Welding Power Supply,” vol. 51, no. 1, 2013.

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