A series-parallel load-resonant converter for a controlled-current arc-welding power supply
A power supply incorporating a series-parallel load-resonant converter, capable of very efficient operation over a wide range of output power is presented. The series-parallel load-resonant converter is shown to have three pairs of resonant frequencies. Operation of the circuit at each of these resonant frequencies maintains zero current switching and high frequency operation. Design mathematics is developed which allow series-parallel load-resonant converters to be designed with specific resonant frequencies and circuit resistances. A new method of power control for series-parallel load-resonant converters is presented; the power delivered to the circuit and hence the load is shown to var substantially depending on which resonant frequency the circuit is excited at. Two series-parallel load-resonant converters are designed simulated, constructed and tested. There is good agreement between the simulation and experimental results. One of the circuits produces an output current of 200 A while the second demonstrates the new power control technique pulsing between 55 A and 145 A while running at frequencies of 63 kHz and 100 kHz. The new power supply is particularly suited to arc-welding. It contains an active rectifier and draws near unity power factor.