Compact welding rectifiers. Scheme, description

ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING
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Compact welding rectifiers. Encyclopedia of radio electronics and electrical engineering

Free technical library

Encyclopedia of radio electronics and electrical engineering / welding equipment

I offer two compact welding rectifiers.

The first one is combined with a toroidal transformer and an air cooling fan. The rectifier bridge itself is assembled here on DL-132-80-10 diodes, installed in the center of the torus on radiator brackets from pieces of an aluminum corner. The thermal regime for high-power semiconductor valves is the most favorable. After all, each of the diodes is washed from almost all sides by an air current sucked in from below (from under the stands) and intensively driven by a fan through a "mini-wind tunnel" - the inner funnel (window) of the torus.

True, for such a free "blowing" I had to worry about the optimal layout of the unit. In particular, it should be provided that there are holes of a relatively large diameter both in the base and in the coupling cover, to which (due to the existing flange) a three-phase multi-bladed fan UVO-2,6-6,5-U4 is attached. And in order for the air intake to go from below without interference, the height of the supports screwed to the base must be at least 20 mm.

Now a few words about the features of connecting a diode bridge to a welding transformer. With intensive use of the welding machine, one of the outputs of the diode bridge is connected to a common terminal, and the other, being "floating" in this case, is docked with one or another output of the transformer. If voltages of 6 V, 12 V, 18 V, etc. are required, then both inputs of the diode bridge are made transient ("floating").

DC welding machine (click to enlarge): 1 - stand (wood, plywood, s20, 4 pcs.), 2 - base (plywood, s10), 3 - countersunk head screw (8 pcs.), 4 - pin terminal (4 pcs.), 5 - terminal lug (4 pcs.), 6 - M6 stud (bronze or brass, 4 pcs.), 7 - M6 nut (bronze or brass, 16 pcs.), 8 - washer (bronze or brass, 20 pcs.), 9 - wing nut M6 (bronze or brass, 4 pcs.), 10 - rotary folding handle (from decommissioned radio equipment, 2 pcs.), 11 - phase fan UVO-2,6-6,5, 4-U2 (in a round case with a 12 μF phase-shifting capacitor), 4 - M3 screw with Grover's washer (13 pcs.), 10 - coupling cover with a central hole for the fan (plywood, s14), 15 - toroidal core (from asynchronous stator motor), 16 - primary winding of the transformer (number of turns, taps, wire diameter - calculated), 17 - insulating layers (thickness and quantity - calculated), 1 - ring gasket (electrotechnical cardboard, s 2,5 ... 2, 18 pcs.), 1 - external insulation (winding with varnished tape in 2 - 19 layers), 75 - bracket (aluminum corner 50x2, 20 pcs.), 132 - semiconductor diode DL-80-10-4 (21 pcs.), 60 - central bracket (aluminum corner 60x22), 6 - a screw with a semicircular head (1 pcs.); D2 and DXNUMX - according to the dimensions of the fan.

The rectifier improves the ignition of the arc, as the open circuit voltage increases, and improves the quality of welding. In addition, we must not forget that more heat is generated at the positive terminal. And this property, as they say, is a sin not to use when welding thin-walled parts (here "+" is supplied to the electrode).

Well, now about my second development. This is an autonomous rectifier (it can be used with almost any device for a current of 200 A). With a simple circuit diagram of a diode bridge, this design cannot generally be called primitive-standard. Its unusualness lies in the use of two groups of bipolar diodes - V200 and VL200 (their external difference is, respectively, green and crimson cases). This means that there is a real opportunity to connect diode radiators in each of the groups. That is, in one group on the radiator it turns out "+", in the other "-". Homogeneous are connected with M8 studs, and a rubber gasket is installed between dissimilar ones. The whole structure is extremely compact and reliable.

"Kid" rectifier for "welder" (click to enlarge): 1 - diode radiator (4 pcs., bundled in pairs), 2 - network panel (textolite, plywood, s10), 3 - M8 stud (bronze or brass, 4 pcs. .), 4 - M8 nut (bronze or brass, 18 pcs.), 5 - washer (bronze or brass, 28 pcs.), 6 - M8 terminal bolt (bronze or brass, 2 pcs.), 7 - powerful rectifier diode V200 (2 pcs.), 8 - powerful rectifier diode VL200 (2 pcs.), 9 - output from the rectifier to the load (2 pcs.), 10 - rectifier panel (plywood, s10), 11 - insulating gasket (bicycle chamber rubber) ; a) - a schematic diagram of a rectifier bridge.

And one more feature is obvious here: the leads of the diodes can be used as handles - for carrying the rectifier. Moreover, the mass of the entire device does not exceed 5 kg.

Author: O.Vladimirov

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