SMPS welding inverter soft LVI switcher. - diyAudio
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Old 16th June 2015, 04:10 PM   #1
kees52 is offline kees52  Netherlands
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Default SMPS welding inverter soft LVI switcher.

Hi There

My old post was closed because of this answer..

discussions about equipment working directly off the mains is not allowed in this board...

But here I see a three fase 1000 amps 10 kw version, how this come possible if it is not alowed?.

Oke I am busy with the welder inverter and have now some sims done, the MIG voltage feedback has also a Current setup for TIG welding.

I use a LVI coil who regulate the soft switching of the inverter, but I need to build it if I am shure about the work.

It looks in LT spice very stable, a welder inverter is also a learning curve for me making a supply for audio amps, the new chips these days are interesting, ZVS soft switch is also very clean for amp supplys.

Last three pictures has a simplyfied feedback without hot start for mig only, using a oscillator to make pwm, I can romove that and use the controller ramp output also, if allowed, not shure, these are really stable full bridge inverter

Regards.

kees
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Last edited by kees52; 16th June 2015 at 04:14 PM.
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Old 17th June 2015, 04:27 AM   #2
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Care to share your asc file?


Regards
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Old 17th June 2015, 07:45 AM   #3
kees52 is offline kees52  Netherlands
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Quote:
Originally Posted by rikkitikkitavi View Post
Care to share your asc file?


Regards
Here it is.

I have a lot of singulair errors, sometimes not, the opamps do this, change them works but I need rail to rail opamps for this.

another one here, the feedback came from a welder schematic, tig and mig new-test-mig.zip

regards
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File Type: zip mig-test.zip (5.4 KB, 6 views)
File Type: zip new-test-mig.zip (6.0 KB, 5 views)

Last edited by kees52; 17th June 2015 at 08:11 AM.
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Old 17th June 2015, 10:35 AM   #4
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Ah,thanks but some of the parts are non standard, the IGBTs and UC3875 phase shift controller fex.
Did you build these subcircuits yourself?

My comment is that if it works in simulation you have a have a good chance to get it to work. But layout and parasitics , and component parameter variation can lead to disastrous failures.

You have counteracted some by adding passive components of course.
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Old 17th June 2015, 11:37 AM   #5
nec3 is offline nec3  Turkey
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Adding spread parasitic components in the circuit and simulating it with them will give you more accurate results for real life. Especially parasitic inductance at the emmiters of IGBTs. You can add 5-20 nH depending on the structure of PCB you plan to use in emmiters and some milliohms at the output and see results.

During my plays with layout parasitics, i saw they cause no catastrophiy but some loss at power output. It was a two-transistor forward converter based on 3845 with an output 150 A DC.

Edit: And the coupling coefficient of output transformer K must be less than 1.

Last edited by nec3; 17th June 2015 at 11:47 AM.
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Old 17th June 2015, 02:10 PM   #6
kees52 is offline kees52  Netherlands
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Hi Guys

The models I have came from a Russian site, I did not make them myselfs.

I do now about parasitic components, the pcb layout for a inverter of this kind is very important, but a globe in series when testing will give I hope less disastrous failures.

Afcourse I have to follow recommendations about the chip, keeping it far away and give them very clean supplys.

I go try with some adding inductance on the igbts and see what happens, I let you now.

models please translate it is cyrillic. there are the models name valvol.

What concerns coupling of transformers, how much leakage is real in lwspice?, I need also for resonant coil saturation.
I did use coupling 0.98 now.

regards

Last edited by kees52; 17th June 2015 at 02:23 PM.
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Old 17th June 2015, 02:33 PM   #7
kees52 is offline kees52  Netherlands
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As you see put a inductance in series with coil it start blow itselfs, but maybe I have not did fill in the richt values, I am quite new for ltspice.
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Old 17th June 2015, 03:09 PM   #8
nec3 is offline nec3  Turkey
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" how much leakage is real in lwspice?"

There is no formulation as far as i know for leakage inductance. It is very much dependant on the physical construction of the transformer.
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Old 17th June 2015, 03:17 PM   #9
kees52 is offline kees52  Netherlands
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Quote:
Originally Posted by nec3 View Post
" how much leakage is real in lwspice?"

There is no formulation as far as i know for leakage inductance. It is very much dependant on the physical construction of the transformer.
Good question, when I make K 0.98 supply crashing ,boom.

I do not now if igbt models have already the parasitair induction in them, I am not a good model maker.

but see what happens if leakage is bigger on picture, not good, so you see also that pcb board is very important, some when I see a cheap smps supply of a pc, I scratch behind my ears of hmm, that it do work with such a pcb, these are not really without parasitair inductions.

Modern chips are better also the igbt, and yes a pc supplt is not a welder.

picture two is with K = 1 first with K = 0.99

Did try sim the schematic and yes again trouble, LTspice is very troublesome when schematic is more complicated, with all setting on it does not prevent with trouble smps controller, cause are the feedback opamps, but yesterday it did work, maybe trouble with models as I read sometimes.

regards
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File Type: jpg ScreenHunter_595 Jun. 17 17.06.jpg (105.8 KB, 8 views)
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Last edited by kees52; 17th June 2015 at 03:27 PM.
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Old 17th June 2015, 03:41 PM   #10
nec3 is offline nec3  Turkey
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I think all simulators will make problem for such large circuits if not everything is adjusted correctly.

There must be something you can change on the Control Panel of LTSpice to force it run. I am not good at LTspice neither.
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