Large- and Small-Signal Modeling and Control Strategy for Multi-Output Welding Power Supply

Welding technology is a key aspect of the manufacturing industry. With the application of aluminum alloy expanding to more applications, the demand for advanced welding technology for aluminum alloy is constantly increasing. The aluminum alloy welding process requires a multi-output welding power supply to improve aluminum alloy welding quality. In this paper, we design a novel type of multi-output converter that outputs dual DC or single AC according to different welding process requirements and analyze its working principles in detail. Considering the influence of load current variation on the circuit’s performance, we established small-signal models of the DC and AC working modes and large-signal models of the system. Based on these models, we designed a control algorithm for the proposed multi-electrode arc welding power supply. Finally, we constructed an experimental prototype and demonstrated the feasibility of the control strategy. Based on the welding power supply designed in this paper, the welding process control of aluminum alloy can be more accurate, resulting in better welding quality.