Welding-charging-starting device. Scheme, description

ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING
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Welding-charging-starting device. Encyclopedia of radio electronics and electrical engineering

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Encyclopedia of radio electronics and electrical engineering / welding equipment

I would like to take on the welding-charging-starting device, but the winding work in the manufacture of a powerful transformer, a choke scares me off. Yes, and the installation of an electronic control unit for thyristors, I'm afraid I won't be able to ...

Indeed, it is possible to simplify the development that interested readers by leaving in it a power transformer, two "electric" T160s and a thyristor control unit. In the manufacture of the latter, by the way, it is easy to do without winding operations, if the transformers (both "silovik" and "impulse") are taken ready-made (fortunately, the domestic industry has long since established mass production of good analogs).

Since the secondary windings ll-1 and II-2 of the power transformer T1 are separate, when they are connected in series, you can get a common point without any problems, which means that instead of a diode-thyristor bridge, you can get by with just a pair of the aforementioned T160. Moreover, using elementary jumper switches (copper bars) on a homemade terminal block (bolted insulator plate), it is easy to turn this basic device into any of the options for a welding-charging-starting unit that is truly necessary "for a home, for a family", especially for the economy.

Take, for example, a circuit solution for the implementation of the WELDING and CUTTING mode of metal on an adjustable alternating current. Thyristors VS1c and VS2 c are connected here in such a way that they act as an analogue of a triac. Windings ll-1 and ll-2 work as one large secondary. As a result, at the output of such a device, we obtain an adjustable alternating voltage from 0 to 60 V, which is quite enough for welding, as well as cutting metal.

A completely different matter is a circuit solution for the implementation of the CHARGER mode. With such a circuit for switching on thyristors, we will get at the output of the rectifier (terminals "+" and "-"), in a rough approximation, half of the voltage that is induced in the entire secondary winding of the power transformer T1 s, but this is quite enough to charge any battery.

It makes sense to mount the proposed simplified welding-charging-starting device, like its most "complete" version, inside a metal frame made of a 15x15 mm steel angle. Dimensions - in place, based on the real dimensions of a power transformer placed in series, two "trolleybus" T160s and a thyristor control unit.

It is advisable to install on the front panel: a mains voltage switch with automatic protection, a NETWORK indicator light, a 30 V DC voltmeter, a 50 A DC ammeter with an on-off toggle switch, a VOLTAGE potentiometer for adjusting the operation of power thyristors, terminals "+" and " -" for connection to the car battery both when charging it and for starting the car with a discharged battery, terminals for connecting the cable and "ground" when welding and cutting metal. Well, under the top cover of the device, you can fix a contact block with changeover copper tires to switch to the WELDING and CHARGER modes.

Welding-charging-starting device
Three-dimensional diagram of the installation of jumpers on the switching block in a simplified welding-charging-starting unit

Welding-charging-starting device
Switching options in WELDING (а) and CHARGER (b) modes

The algorithm of work on a simplified welding-charging-starting device is not much different from the procedure recommended for the previous "full" analogue. In particular, when preparing for welding, it is necessary to switch the copper bars on the terminal block to the WELDING mode, connect the welding cable and the "ground" to the corresponding terminals on the front wall. Now, having selected the required current by setting the VOLTAGE potentiometer, you can start welding.

To work in the CHARGER mode, you need to connect the battery to the "+" and "-" terminals on the front side of the device, switch the copper busbars on the terminal block to the CHARGE position, set the required charge current with the potentiometer of the power thyristor control unit (guided by the ammeter).

Well, for the START mode, it is enough to transfer the device to the CHARGED state, apply an increased current (up to 50 A) to the battery terminals when the car starter is turned on for a short time.

Author: A.Shikhansky

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