Design and Analysis of Welding Power Supply with Active Current Injection PFC System

This study deals with the design and simulation of an enhanced PFC system for a front-end three-phase rectifier based on current injection utilized for gas metal arc welder. Compared with traditional arc welding machines, the suggested arc welding power source (AWPS) is the best choice for its benefits such as simple circuit, superior energy productivity, and capability to achieve unity PF with good weld bead quality and best arc stability. The proposed welding system is designed to function under a variety of load power while enhancing the efficiency of AWPS and power quality (PQ) in AC mains. A closed-loop fractional PI control system with one voltage detector is used to realize voltage and arc current controls with fast response. MATLAB program was exploited to simulate the suggested AWPS and the performance of studied system is examined with that of a Diode Bridge Rectifier (DBR). The suggested structure offers a high PF and a significant decrease in input current THD under rated load conditions.