Download EV Welding Technologies

IGBT WELDING TECHNOLOGY
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IGBT Welding machine has 3 kinds of technology, which are
dual switch forward technology, half bridge technology and full bridge
technology. For now, we regularly use half bridge and full bridge for
welding machine.
In the market, The 120A around single PCB board machine usually use
the half bridge technology, with two transistors. This machine can
reduce the cost, but it is low power, low duty cycle which around 2030%, and low welding effiency. Suitable for DIY.
The normal three PCB machine usually use full bridged technology ,
great power, high duty cycle. Use 4 transistor. The cost is much high
than the single board machine, but high effiency. Suitable for DIY and
factory.
Dual switch forward technology
• This technology is not very good on making the
welding machine because its unstable characteristic,
and high requirements of the components, we are
not regular use this technology for welding, This
machine need pay attention on the design details,
otherwise, it will be easy damage, and hard to repair.
Half bridged technology
• The advantage of the half bridged technology is low cost, save
the components, simple drive circuit, no need for leak
resistance.
• The disadvantage is IGBT needs additional absorbing circuit,
has through risk because of the Miller effect. IGBT needs more
work as the full bridged technology, caused low duty cycle.
Regularly, the duty cycle is 20-30% around.
• It is very low price in real current 120A and below current. But
low duty cycle.
Full bridged technology
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The advantage of the full bridged technology is High transformer efficiency,
high power and the duty cycle can be more than 90%, even 100%. High
transformer efficiency.
Disadvantage is that IGBT system needs additional absorbing circuit. It has
through risk because of the Miller effect. Needs additional circuit for the
transformer to prevent magnet bias.
Requirement of the components is high, complicated circuit.
The cost of the full bridged technology machine is much high than other
technology, but it is high power, high duty cycle. But because of the technology,
it needs additional circuit to improve the machine’s ability.
The difference between Half bridged
and Full Bridged technology
• From the diagram above , we can see that for 120A
machine, the most important difference is the quantity of
the transistors. Half bridged use less transistors, and
simple drive circuit, so that is why it is less cost. Full
bridged machine use 4 transistors, complicated circuit,
so it is high power and high duty cycle, but higher cost.
Technology Half bridged
Transistor
2
Drive circuit simple
Full bridged
4
complicated
Transformer
primary side
Wire diameter thick More turn number
Input filtering
2
No need
Leak circuit
1
No need
EV MINI machine’s technology
and advantage1
• Use the stable full bridged technology, the unique
radiator design and structure improved the heat
transfer, make the machine more stable and high
duty cycle. Our mini machine can be 100% duty cycle
in normal temperature.
• Use the SMT technology, not only save the space
inside the machine, but also improve the quality of
the machine.
• Use the Nano core technology transformer, make the
machine more stable and high efficiency.
• Use the special two board structure, better heat
transfer. Make the machine high duty cycle.
• Use the best quality capacity , can make the machine
more life and high welding quality, even can work in
very low voltage.
EV MINI machine’s technology
and advantage2
• Use 8038 Fan, high speed, good performance and quality,
improve the machine efficiency, make the machine more duty
cycle.
• Intelligent anti-stick function, this function can make the
machine to take the electrode from the welding easy when arc
broken
• Intelligent arc force system, this function can provide the
additional current when do the welding process, reduce the arc
broken and improve the welding efficiency.
• Intelligent hot start function, when the electrode touched the
welding board, make the high welding current, improve the arc
strike and welding efficiency.
• can weld in very low voltage environment, works very well in
160V voltage. Suitable for the unstable voltage are.
EV MINI DATA
DUTY
165A
100%
Electrode
Ø1.6Ø5.0mm
No-load Voltage
70V
Output current
20-165A
Efficiency
80%
Input current
30A
Force
YES
Antiplastering
Yes
Hot-Start
Yes
N.W
2.66kg
Size
26X11X16cm
EV MINI DATA
Component
IGBT
Diod
Temperature protect
Supplier
ST
PEC
TEMPREL
Remark
4PCS
4PCS
1PC
Capacity
SINECON 3PCS
Relay
SONGLE
1PC
Fan
Bridge
BISEN
PEC
8038
1PC
EV MINI Temperature testing report1
Room temperature 24℃-26℃ Load testing
IGBT1 （℃）IGBT2（℃） IGBT3（℃）IGBT4（℃）
1’ Min
46
41
39
38
2’ Min
53
46
45
42
3’ Min
57
48
49
46
4’ Min
59
49
50
47
5’ Min
60
49
52
47
6’ Min
61
49
52
48
7’ Min
61
50
53
48
8’ Min
51
50
55
50
EV MINI Temperature testing report2
Room temperature 24℃-26℃ Welding testing
Electrode IGBT1 （℃）IGBT2（℃） IGBT3（℃） IGBT4（℃）
1st
53
46
42.5
43
2nd
60
49
48
50
3rd
63
51
52
52
4th
63
50
50
53
5th
64
51
52
53
6th
66
53
53
54
7th
67
53
55
54
8th
67
53
55
54
Why EV Welding High Duty Cycle？
• From the Testing report1&2 above, we can
see that, when the room temperature is
24℃-26℃, The highest temperature of the
loading test IGBT is 61 ℃. And the highest
temperature of the welding test IGBT is 67
℃. After 6 minutes, the temperature is
nearly stable. The protect temperature is
85 ℃. Testing IGBT temperature is much
lower than the protect temperature. So the
welding machine will not be protect when in
normal room temperature.
EV MINI Temperature testing report3
Room temperature 35 ℃，Finally 45 ℃
IGBT1 （℃）IGBT2（℃） IGBT3（℃）IGBT4（℃）
1’ Min
59
57
61
46
2’ Min
66
65
70
50
3’ Min
72
72
77
69
4’ Min
77
76
80
74
5’ Min
79
78
81
75
6’ Min
81
80
85
78
7’ Min
82
83
86
78
EV MINI protect room temperature？
• From the testing report2, we can see
that, when the room temperature from
35℃ rise to 45℃, for the loading
test, when reach to 7 minutes, the
IGBT temperature is 86 ℃, The
machine protect. After 45 seconds,
machine temperature reduce, the
machine can continue to work.
Why EV machine’s price is higher
than the single board machine?
• For now, in the market, most of the single board machine is belong
to the half bridged technology. Usually, this machine’s real current is
100A and 120A. This machine use 2 transistors for low current
structure. But 2 transistor can not make high power machine, if
increase the power to above 120A, the machine will be overload,
even damage. Besides, some bad factory use the recycle (second
hands) components for the welding machine, the price is very low,
but the products are very unstable. And the life is very short.
Customers will complain it.
• EV machine promise use the new components for all the machine,
great quality. And our machine use the 2 boards full bridged
technology. 4 transistors can make the machine more power, even
can be 180A real current, even above. Use the best 38 fan. These
technology will much improve our machines’ technology. And make
the welding machine high quality and high duty cycle, 100% duty
cycle.
EV machine’s advantage？
• Smart, Tiny, Portable , It is only 2.5kg. Can easy
carry to work at height.
• The machine is smart, but with great power, can
weld 5.0mm electrodes. Good efficiency. Suitable
for DIY, family factory and big factories.
• High duty cycle, can work for long time with no
stop protect. Machine will be not protect in
normal room temperature. improve the welding
efficiency, reduce the working time.
• The machine got the intelligent function. Antistick, Arc force and hot start, to improve the
welding efficiency.