Design of a new industrial AC/DC/AC welding converter, starting from the analysis of the current model at risk of obsolescence.
The approach involved assessing the performance of the existing converter to define specifications that would evolve the system in terms of electrical characteristics (improvement of Power Factor, reduction of THD – Total Harmonic Distortion, adjustable DC link voltage), performance (welding speed and quality, machine safety), and connectivity (integrated HTTP and TCP/IP servers in addition to the existing communication buses).
The architecture features modular digital hardware, multiprocessor and multicore control, and state-of-the-art SiC-based power electronics.
Re-design of a power converter for industrial welding
3 phase input, 1 phase output with PWM output current parametrization (3kHz, 350AIpeak)
Analysis and benchmarking of the old power converter (e.g. PF, THD, PWM control, ecc.)
Definition of both HW and SW requirements
Improvements of the electrical characteristics and working conditions
Test setup for voltage and current analisys on a working machine
Altium designer for digital and power electronics
Solidworks design for power dissipator and box
Matlab/Simulink and C/C++ firmware programming
Electrical designEnergyFirmware developmentHardware designPrototype
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