Abstract

Arc welding machines are large, heavy devices that transform an alternating current (AC) input into a high-current, low-voltage, direct current (DC) output. These machines traditionally require electromagnetic transformers that account for the large size and weight. While the cost of high power silicon devices has been decreasing, the cost of steal and copper required for electromagnetic components has been increasing. This parity has created an opportunity for a cost effective DC switching welder to be introduced to the consumer market. Under the commission of a local welding equipment manufacturer, this study sets out to develop and prototype the electronics necessary for an affordable, portable battery-powered welding machine. The design is implemented with a high current buck switching circuit as well as an assortment of feedback, control and safety circuitry necessary to complete the product. Using simulation, bench validation and the bounds of real world cost limitations, this project will develop a market-ready welder.