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Design of a welding power supply with wide input voltage range

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Abstract

This paper proposes a power supply for welding that can adapt to a wide range of input voltages. The phase-shifted full-bridge (PSFB) converter, which is widely used as a welding power supply, is not suitable for applications where there is a wide input voltage range because of an increase in the circulating current and high-voltage stresses on the switch devices when a high input voltage is applied. To address this issue, a method to change the structure based on the input voltage is proposed by dividing the primary-side high-frequency inverter stage of the PSFB converter into two and adding path switches that can be configured in series or in parallel. The proposed circuit can lower the switch devices withstand voltage through structural changes and operate in a duty ratio with narrow fluctuations on the wide input voltage, which helps to improve the overall efficiency. The validity of the proposed method was verified through a comparison with existing topologies on a 6.6 kW prototype.

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Acknowledgements

This work was supported by a Korea Agency for Infrastructure Technology Advancement (KAIA) grant funded by the Ministry of Land, Infrastructure and Transport (Grant 21HCLP-C162885-01) and the Vehicle Industry Technology Development Program funded By the Ministry of Trade, Industry & Energy (Grant 20018958)

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Authors and Affiliations

  1. Department of Electrical Engineering, Myongji University, Yongin, Korea

    Jin-Su Kim, Seung-Min Nam, Dae-Young Hong, So-Jeong Kong & Jun-Young Lee

  2. Korea Railroad Research Institute, Uiwang, Korea

    Young-Joo Kim

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  1. Jin-Su Kim
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Correspondence to Jun-Young Lee.

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Kim, JS., Kim, YJ., Nam, SM. et al. Design of a welding power supply with wide input voltage range. J. Power Electron. 23, 1141–1149 (2023). https://doi.org/10.1007/s43236-023-00639-7

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