Analysis of welding conditions at synchronous operation of resistance welding machines

Abstract The paper is devoted to analysis of power losses in a resistance welding machine including supplying system and examination of welding conditions of the welding machine current in a case of synchronous (simultaneous) operation of multiple welding machines, i.e., during the conduction of welding current. Analysis of the most important contributors of power losses generated on the current path between a power source and the welded joint is carried out. The analysis is carried out for a DC (direct current) welding machine with power electronics inverter. AC (alternating current) welding machines are also taken into account. The analysis is divided in two parts. The first one is the analysis of single welding machine operation, while in the second part, coexistence (mutual operation) of two synchronous welding machines is considered. The analysis is based on results of numerical and experimental investigations. The first one is focused on calculation of power losses in the energy path (including a Sankey type power loss distribution diagrams), and the second one is based on experimental tests carried out to determine the diameter of the weld nugget and the strength of the joints, for cases of reducing the welding current. An example of simultaneous operation of welding machines was presented and discussed. The percentage voltage drops and power losses in the entire power supply path of the resistance welder are shown. The analysis carried out is extremely important from this point quality of welded joints.