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CHAPTER 1
INTRODUCTION
1.1 THE BACKGROUND
Welding is a way of heating pieces of metal using electricity or a flame
so that they melt and stick together. It can simply be defined as the
process of joining two or more pieces of metal to make the act as a
single piece. This is often done by melting the work pieces and adding a
filler material to form a pool of molten material that cools to become a
strong joint. Because of its strength, welding is used to join beams
when constructing buildings, bridges and other structures. Welding can
also be used to join pipes in pipelines, power plants at the
construction sites and in home appliance. Furthermore, welding is used
in shipbuilding, automobile manufacturing and repair, aerospace
applications. There are many kinds of welding which include arc welding,
resistance welding, gas welding among others. Emphasis will be laid on
arc welding because it is the most common type of welding as well as the
main aim of this project.
Arc welding is the process of welding that utilizes an electrical
discharge (arc) to join similar materials together. Equipment that
performs the welding operation under the observation and control of a
welding operator is known as welding machine. To solve the problem of
weight and size of conventional arc welding machine, it is necessary to
design an inverter. The inverter provides much higher frequency than
50Hz or 60Hz supply for transformer used in welding. So transformer of
much smaller mass is used to permit the handling of much greater output
power. The welding noise produce by conventional arc welding machine is
reduced by selecting the operating frequency over the hearing of human
ability. The choice of 20Khz for the inverter type arc welding machine
was determined to meet the above expectation. The output welding current
is controlled by controlling the power supply for transformer at high
frequency. This power supply is provided by a frequency inverter. Power
switch IGBTs (Insulated Gate Bipolar Transistor) or MOSFETs is used for
the inverter design due to its high switching. The control circuit use
to control the output welding current is design to drive the power
switch at high frequency. Insulated Gate Bipolar Transistor power switch
is more efficient and less prone to failure than MOSFETs power switch.
1.2 AIMS AND OBJECTIVES OF THE PROJECT
The main aim and objective of this project is to design and build and
arc welding machine that operates on 36vdc at variable frequency which
of benefit to urban area. This reduces the weight and size of the
transformer use for welding. To have an arc welding machine that is more
efficient which produce neat welding.
1.3 SIGNIFICANT OF THE STUDY
The significant of this project is that it seeks to develop an arc
welding machine that is cost effective, strong and portable. Not only
that the arc welding machine is strong and portable, it is also mobile.
1.4 LIMITATION OF THE PROJECT
The project has certain limitations which are mentioned below.
This project cannot weld bigger gauge of metals.
The welding time and power depends on the battery input power.
You are to have bands of battery for reliability when using battery.
The machine must be used by a qualified welder. Welding can endanger
the operator or people near the working area. Therefore, the performance
of welding and cutting must only be done under the comprehensive
observation of all relevant safety regulation.
Switch function modes during welding could potentially damage the
equipment. A safety switch is necessary to prevent the equipment from
electric leakage. Use only high quality welding tools and equipment with
this inverter type arc welding machine.
1.5 PROJECT REPORT ORGANIZATION
The organization of the project report is well detailed and vast in its
coverage. It covers all the activities encountered during the research
work. The first chapter is the introductory chapter which covers the
background, project objectives, project justification, and scope of the
project. Chapter two presents the literature reviews. Chapter three
covers the system analysis and design methodology in details. Chapter
four presents the system implementation which entails the circuits
diagram of different stages and also the complete schematic diagram with
necessary calculation involve in the design. Chapter five is emphasis
on conclusion, problem encountered during project design,
recommendations and suggestion for further improvement. Fig1.1 depicts
an overview of project report organization.
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