Calculation of the welding transformer. Scheme, description

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Electric welding. Calculation of the welding transformer. Encyclopedia of radio electronics and electrical engineering

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Calculate low power welding transformer, designed to operate on AC 220 V, 50 Hz and providing the maximum welding current I_М = 150 A.

Maximum arc voltage, corresponding to the maximum welding current, can be calculated by the formula:

As mentioned earlier, the open circuit voltage U_xx (voltage on the secondary winding of an unloaded transformer) should be 1,8-2,5 more than the maximum arc voltage, i.e.

With increasing U_xx improves stability and initial ignition of the arc. However, GOST95-77E limits the maximum operating voltage Uхх at the level of 80 V. Let's choose the open-circuit voltage U_xx= 65 V, which will provide the best conditions for arcing and does not contradict the requirements of GOST.

For further calculations, let's assume that our magnetic material has a maximum induction B_т = 1,42 T

Will find overall power of the welding transformer P_г:

According to the well-known formula, we determine:

where J is the current density in the windings (8 A/mm2 for copper (Cu), 5 A/mm2 for aluminum (Al) and 6,5 A/mm2 for a combined copper-aluminum (CuAl) winding); F - network frequency, Hz; TO_o - window filling factor (0,33-0,4); To_с - steel fill factor (0,95).

Let the primary winding be made of copper wire, and the secondary - aluminum, then:

For rod transformers, the following are recommended: size ratio:

where

If Z = 4, then From here you can find core size a:

We choose a \u4d XNUMX cm. Knowing the size a, we find dimensions c, b, h:

Define EMF of one turn of the transformer:

Number of turns of the secondary winding:

Cross-section of aluminum wire of the secondary winding:

(you can use an aluminum bar with a section of 5x6 mm2).

Number of turns of the primary winding:

Will find maximum primary current:

Cross-section of the copper wire of the primary winding:

Since the transformer is rod, the primary (and secondary) winding is on two coils:

if the coils are connected in parallel, then they must contain 230 turns of PEV-2 wire 1,9 mm (2,827 mm2);
if the coils are connected in series, then they should contain 115 turns of PEV-2 wire 2,7 mm (5,7 mm2).

Author: Koryakin-Chernyak S.L.

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Comments on the article:

Alexander
The first competent calculation that came across to me on the Internet! [up] And then the rest will climb into the wilds of the forest and it is not clear what they want to calculate!

Vladimir
Very intelligible and understandable. Thanks to the author, rarely when they paint like that.

Volodymyr, Kiev.
I am a doctor by profession, electronics is just a hobby, but after viewing the article I have to say this: "He who thinks clearly, writes clearly!" Respect and respect to the author!

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