Design and Analysis of Soft Switching PWM DC-DC Power Converter with High-Frequency Transformer Link for Portable Arc Welding Machine

Conventional welding machines that are available in the market, runs by Grid power (AC) are bulky in size and are not cost-effective. Those existing systems have the problem of low power factor and high harmonic content at the utility grid interface. This paper presents a detailed analysis of various power converters for an arc welding process that will improve the power quality with enhanced efficiency. The analysis covers full-bridge and half-bridge DC-DC converter with an isolated high-frequency transformer and LC filter. Both analyses were carried out by boost and without boost topology using PSIM simulation software. The circuit and design parameters for high-current DC-DC converter based spot welding machines with higher PF and lower THD are also analyzed.