CHAPTER ONE

INTRODUCTION

1.1. Background of the Study

Welding is a fabrication process, a method of joining metals in which heat

and /or pressure are applied to the area of contact between the two

components; a filler metal may be added into the joint depending on the

welding process. There are many kinds of welding, which include arc

welding, resistance welding, gas welding among others. Emphasis will be

laid on arc welding because it is the most common type of welding as well

as the main aim of this design. In arc welding, an electric arc is generated

between a base metal and electrode. The heat of the arc melts the base

metal and welding consumable to produce the weld metal for joining

structural components. The most popular of the welding machines uses the

arc welding methods, which include the

(i) SMAW – The stick welding or shielded metal arc welding

(ii) GMAM – The tig welding gas metal arc welding

(iii) GTAM – The tig welding or gas tungsten arc welding.

Others are brazing, soldering and oxyacetylene welding. In the automobile

industry the resistance spot welding (RSM) is one of the most efficient
material-joining processes, it utilizes currents in the range of 1 – 200KA

with durations ranging from a few cycles to one second to generate joule

heating. RSM transformers operate within a middle frequency range of

around 1kHz. In this research the welding system constructed uses low

frequency transformer that operate at the utility mains frequency of 50 or

60 Hz with variable current selectors to avoid power quality problem. Power

quality problem refers to voltage current and frequency deviation from

nominal value in electrical distribution and utilization system. Any

significant deviation in the waveform magnitude, frequency or purity is a

potential power quality problem which may result in failure or

malfunctioning of equipment. The current selector introduced in this

transformer help to maximize the power quality problem association with

a.c electric power systems, that operates at a sinusoidal waveform of 50 or

60 Hz and rated voltage magnitude. The deviations depends on the

duration and magnitude which help to categorize the voltage deviation as

voltage sags, interruption, over voltage, under voltage, transients, voltage

imbalance and voltage flickering. In many electric welding systems, a

potential difference of 50-70 volts is required to strike an electric arc. After

the arc is struck, an essentially constant current supply is desired .The

welding transformer converts the high voltage and low current from the

utility mains into low voltage and high current, usually in the range of 55 –

590 amperes. In this transformer the variable current selector help to

maintain the constant current supply desired.

1.2. Problem statement

Sequel to the vast need and use of iron rods, metal bars and pipes, right

from the domestic level up to industrial extent, the arc welding machine

was built in order to ensure that the ulterior motive of the manufacturers of

these products (iron rods, metal bars and pipes) by their manufacturers is

being achieved as part f technological advancement. With the electric Arc

welding machine, the difficulty of using iron rods, bars and pipes in

construction works has been removed. Equipment that performs the

welding operation under the observation and control of a welding operator

is known as welding machine. To solve the problem of weight and size of

conventional arc welding machine, it is necessary to design an Arc welding

machine.
1.3. Aim & Objectives

The aim of this project work is to design & construct an Arc welding

machine with output voltage digital display . The objectives to carry out the

implementation are:

1. To dicots the iron core in E & I shape.

2. To fabricate a match able robin which the copper coil will be wind on.

3. To properly insulate the copper coil.

4. To get a good winding machine to wind the coil round the robin & fix it

properly in the iron for lamination.

1.4. Scope of the project

The Arc welding machine is specially designed for industrial and agricultural

welding. It is powered from single phase, 240v 50Hz power supply. It is

operated from 30A socket. During use; when tap changing, the entire

machine should be off before tap changing the load terminal when welding.

When there is low welding current and due to variation of power supply, a

higher tap should be used to increase the welding current. This electric Arc

welding machine is a heavy duty welding machine which is capable of

welding all or 12 gauges of electrodes, while in operation. For material

cutting, the machine should be tapped at the highest tapping, although

cutting is not very effective at low voltage supply. The out voltage is

displayed in seven segment

1.5. LIMITATION OF THE PROJECT

The limitation of Arc welding machine are listed below

(1) Higher initial setup & cost effective

(2) Atmosphere surrounding the welding process has to be stable (hence

the shielding.

(3) You must put on shaded eye glass during welding process

(4) Higher maintenance costs due to extra electronic components

(5) The setting of plant variables requires a high skill level

(6) Less efficient where there is low voltage main supply

(7) The Radiation effects are more severe

1.6. SIGNIFICANT OF THE PROJECT

The significant of this project work can never be over emphasized. Arc

welding machine has allots of roles to play in our society. The Arc welding
machine has also contributed a lot towards the economy of life in such a

way that when products like machine tools, agricultural tools, machine

parts, motor parts etc. get broken, they could be restored to usage, or

made functional once again through welding, by the use of the electric Arc

welding machine, In that respect, the problem has been solved without

going back to purchase a new one.

REFERENCES

[1] S. Catarina, “Finite element analysis of a welding transformer,” vol. 18,

no. March, pp. 212–221, 2014.

[2] M.Mengesha and M.Adefris, “Power Quality Assessment And Mitigation

At Walya-Steel Industries And Ethio-Plastic Share Company,” vol. 31, no.

2014, pp. 10–17, 2014.

[3] V. Podlogar, B. Klopcic, G. Stumberger, and D. Dolinar, “Magnetic core

model of a midfrequency resistance spot welding transformer”, IEEE Trans.

on Magnetics,doi: 10.1109/TMAG.2009.2031979

[4] Angelo Baggini “Hand book of Power Quality”,John Wiely & Son Ltd,

2008
[5] Rogger G.Dugan, F.McGrangana “Electrical Power quality System”, 2nd

edition, McGraw- Hill, 2004.