Welding

ACERC/DOEE/2014-15/PROJECT/1

CHAPTER 1

ARC WELDER

1.1 INTRODUCTION

This is a transformer type arc welder that will transform incoming high voltage, low amperage

electricity into high amperage, low voltage welding current. An arc welder should be on a separate

circuit of its own with a 50 amp. Breaker and in our welding transformer it will take from power

supply 220volt and 3 amps no load current and it give output of 200 amp range current and 40 volt

at output terminals. And it melts the 8 no. rod to weld any metallic surface. The diagram of the

transformer is shown as below.

FIGURE1.1: ARC WELDING MACHINE


CHAPTER 2

MATERIAL REQUIRED

MATERIAL QUANTITY

1. TRANSFORMER CORE SIZE (9 X 2 & 5 X 2)

2. WINDING CONDUCTOR SWG (10 & 4)

3. INSULATING PAPER CLASS B

4. COTTON TAPE 1 INCH

5. PVC TAPE 1

6. SLIP 4

7. NUTS AND BOLTS 16

8. VARNISH 500 ML

9. BAKELITE SHEET 12 INCHES

10. LUX 4

11. INDICATOR 1

12. HOLDER 1

13. HOLDER LEAD 10 MM (2 METERS)

14. PVC CABLE 6 MM (3 METERS)

15. WELDING RODS 8, 10&12 NUMBERS

16. CLAMPS 4(12 X 2)

17. PLIER 1

18. CUTTER 1

19. SCREW DRIVER 1

20. WRIENCH 2(10-12, 14-15)

21. HAMMER 1( 200 GRAMS)

22. SCISSOR 1

23. CLAMP METER 1


CHAPTER 3

CONSTRUCTION AND DESIGN OF WELDING

TRANSFORMER

3.1. CORE

The performance of a transformer mainly depends upon the flux linkages between the

windings. For efficient flux linking between the windings, one low reluctance magnetic

path common to all windings should be provided in the transformer. This low reluctance

magnetic path in transformer is known as core of transformer.

We used an insulated metal strip (CRGO) of size 92 and 52 for a construction of a core

of a transformer. The size of the core of transformer is 9 of length and 9 inches of

breadth. The weight of a whole transformer core is 14.5 kg. The construction of core is

shown in the figure 2.1 below.

FIGURE 3.1: CORE OF TRANSFORMER (TOP VIEW)

In this we made a core type construction for a transformer, in which we placed two coils in

each of the vertical leg of the core. When these lamination stampings is connected together


form the required core shape as shown in above figure2.1 and their side view of core also

shown in the figure2.2.

FIGURE 3.2: FRONT VEW OF CORE

3.2 COILS CONSTRUCTION

The conducting material used for the windings depends upon the application, but in all

cases the individual turns must be electrically insulated from each other to ensure that the

current travels throughout every turn. The coils used for this transformer are form-wound

and are of cylindrical type. The cylindrical coils will have different layers and each layer

will be insulated from the other with the help of materials like paper, cloth, etc.

2.2.1. Primary winding:

The transformer's primary winding creates a varying magnetic flux in the core and a

varying magnetic field affect on the secondary winding. This varying magnetic field at the

secondary induces a varying electromotive force (EMF) or voltage in the

secondary winding.

For the construction of primary winding coil DCC conductor is used, which come in

different size. For the primary coil we use 2.4 kilograms of 10 SWG aluminium DCC


conductors. The coil made by wrapping the conductors in a cylindrical form layer by layer.

Paper is used to insulate the different layers of the coil.

In the primary winding coil there is 125 numbers of turns in each coil.there are fours

tapping is available in primary coil in every 24 turns.

No. of turns in primary coil each, N1 =125

FIGURE 3.3. PRIMARY COIL FIXED ON A CORE

3.2.2. Secondary Winding

The secondary winding that provides the output to the load or loads. The flux, produced by

primary winding, passes through the core, will link with the secondary winding. The same


aluminium DCC conductor used in primary winding coil Is also used in secondary winding

coil. But size of the conductor for secondary winding is different. We use 2.4 kilograms of

4 SWG alluminium DCC conductors for secondary side coil. We made two coils for

secondary side of transformer. The each coil having a 38 number of turns.

No. of turns in secondary coil each, N2=38

FIGURE 3.4 SECONDARY WINDING FIXED ON A CORE


CHAPTER 4

CONNECTIONS

The connection of the welding transformer done in series connection. The coil is arranged

over the core in alternate form. In the first leg placed primary coil, then the secondary coil.

Similarly on the another leg put secondary coil first then primary coil over the secondary.

These coil insulated from each by using a insulated paper.

FIGURE 4.1: SERIES CONNECTION OF TRANSFORMER

FIGURE 4.2: FINAL VIEW OF CONNECTION


CHAPTER 5

SPECIFICATIONS AND COST

5.1DESCRIPTION:

180 amp air cooled arc welder.

1) Input voltage / phase: 220 volt / 1

2) Current input: 3 amps 27 amps

3) Current output: 70 amps 180 amps

4) Voltage output: 20.8 volt 25.2 volt

5) Welding rods recommended: 1 mm 3 mm

6) Dimensions (Length X Breadth X Height) : 14 X 12 X 14.

7) Weight: 20KG.

5.2 COST

MATERIAL COST (RS.)

CORE - 1200

CONDUCTOR - 1500

ELECTRODE HOLDER - 200

HOLDER LEAD - 260

PVC CABLE - 50

BAKELITE SHEET - 60

VARNISH AND PAPER - 250

COTTON TAPE - 140

LUX - 40

OTHERS - 500

TOTAL COST - 4200


CHAPTER 6

SURVEY

6.1. TRANSFORMER INDUSTRIES IN JAIPUR

1. Uttam Bharat Electricals Private Limited

Road no. 9F, V.K.I Industrial Area Jaipur Rajasthan

2. Indian Transformer Electrical

Road no. 17, V.K.I Industrial Area, Jaipur, Rajasthan.

3.Shree Transformers

V.K.I Area, Jaipur, Rajasthan

4. Swastik Copper Private Limited

Sitapura Jaipur,Rajasthan

6.2. WELDING TRANSFORMER DEALER IN JAIPUR

1. Anil Electrical,

M.I Road, Jaipur ,Rajasthan.

2. Maheshwari Electrical

Mi Road, Jaipur, Rajasthan

3. Avishkar Traders

Shansar Chand Road, Jaipur, Rajasthan.

6.3. RATE LIST

s. no. Brand name Type rating Cost(Rs.)

1. Primeir 4 coil 50-200amp 5500

2. Hi-tech 4 coil 70-250amp 6200

3. Vulcan 4 coil 55-200amp 5800


6.4. COMPARATIVE ANALYSIS

Brand Primeir Hi-tech Vulcan Our welding

machine

Type 4-coil 4-coil 4-coil 4-coil

Rating(amps) 50-200 70-250 55-200 70-200

Cost(Rs.) 5500 6200 5800 4200


CHAPTER 7

ADVANTAGE AND DISADVANTAGE

7.1. ADVANTAGES

Versatility - readily applied to a variety of applications and a wide choice of

electrodes

Relative simplicity and portability of equipment

Low cost

Adaptable to confined spaces and remote locations

Suitable for out-of-position welding

7.2. DISADVANTAGES

Not as productive as continuous wire processes

Likely to be more costly to deposit a given quantity of metal

Frequent stop/starts to change electrode

Relatively high metal wastage (electrode stubs)

Current limits are lower than for continuous or automatic processes (reduces

deposition rate)


CONCLUSION

Welding is a fabrication process that joins materials; usually metals. This is often done by

melting the work-piece and adding a filler material to form a pool of molten material (the

weld pool) that cools become a strong joint. The melting is achieved with pressure

sometimes used in conjunction with heat, to produce the weld. Different power supply can

be used for welding. Arc welding machine transform low voltage low amperage primary

power into the low voltage, high amperage power used for welding at high frequency. This

high frequency transformation helps to reduce the weight and size of the transformer.

The samples were characterized by means of tensile strength, hardness and elongation.

From the investigation it is found that an increase in welding speed increases the tensile

strength and increase in tool rotation speed, decreases the tensile strength.

Welding means the permanent joining together of components by means of heat or

pressure, with or without welding additives. It has specialized in arc welding, one of the

oldest electrical welding processes for metallic materials. This arc between a consumable

electrode as additive material and the work piece, functions as a heat source when welding.

Welding

Documents

core of transformer

transformer core size

construction of core

view of core

core type construction

vew of core

design of welding transformer

transformer type arc