Miller - New Miller Fast Switch Inverter Technology Enables Lighter, More Powerful Welding Machines

8/13/2019 Miller - New Miller Fast Switch Inverter Technology Enables Lighter, More Powerful Welding Machines

1/5

Order LiteratureContact Us

Miller Electric

ProductsWhere To BuyServiceResourcesIndustries & InterestsAbout Us

Our CompanyFollow UsMiller HistoryTrade ShowsNews Releases

EmploymentSite Help

MIG (GMAW) Multiprocess Fume ExtractionTIG (GTAW) Multioperator Induction HeatingStick (SMAW) Submerged Arc GeneratorsEngine-Driven Advanced Mfg. Sys.Plasma CuttersWire Feeders Automation Spot Welders

Helmets & Welding ProtectionWorkstations ConsumablesAccessories Guns & Torches Service Parts

Industrial System Builder Help Me Choose SmartSelectorNew Products Company Store Special OffersRegister Your Product Owner's Manual & Parts ListWelding & Cutting Safety Articles (Tech, How-To, Success)Improving Your Skills Business ToolsVideo Library Industry News BlogDiscussion Forums Resources for SaleEmail Newsletters Fun Stuff

Follow UsManufacturing Racing, Customizing, RestoringFabrication Welding ProjectsConstruction Farm & RanchService Trucks Welding InstructorsIndustry News Blog Discussion ForumsEmail Newsletters

r - New Miller Fast Switch Inverter Technology Enables Lighter, Mo... http://www.millerwelds.com/resources/articles/index.php?page=a

9/28/2011


2/5

Figure 1

Articles & Stories

Home Resources Article Search Technical/InformationalShareThis

New Miller Fast Switch Inverter Technology Enables

Lighter, More Powerful Welding MachinesAPPLETON, Wis., April 8, 2003 As part of its effort to design smaller, lighter and more powerful-per-poundwelding power sources, Miller Electric Mfg. Co. has introduced Fast Switch inverter technology. Products basedon Fast Switch technology will operate at a frequency of 100,000 Hz (100 kHz). This is two to five times fasterthan current inverter or chopper technology and more than 1,000 times faster than conventional weldingtechnology.

A basic premise of welding power source design states that a faster operating frequencyenables the power source to use fewer copper windings and a smaller core in itstransformer and inductor (the heaviest components of a welderFig. 1 thru 4). Miller

plans to introduce its first Fast Switch products in mid-2003. These products will weighless than 13 lbs. and have an output of 150 amps at 30 percent duty cycle.

"Reducing the size and weight of a welding power source increases its portability andconvenience," says Mike Sammons, business unit manager, Miller Electric. "Given thatlabor accounts for 85 percent of a finished weld's cost, portable Fast Switch invertersmake good business sense. The operator can quickly bring the welder to the work site tocomplete jobs faster."

Industries benefiting from portability include mechanical contracting, food/beverage,aerospace, shipbuilding, petrochemical, dairy, maintenance/repair and construction.

Some Miller Fast Switch products will be priced to add appeal to non-industrial welders involved with farm/ranch,

sport aviation and motorsports applications.

Low Stress Leads to Long Life

Miller anticipates that products based on Fast Switch technology will exceed the reliability rating of existinginverters, and inverters such as Miller's Maxstar TIG/Stick products already set the industry standard forreliability in their category. Fast Switch technology increases reliability because it reduces the stress on the powerswitching semiconductor, called an IGBT.

Figure 2 Figure 3

With semiconductors, the secret to a long life is to reduce their operating temperature. There is an equation whichbasically states that every 10 C temperature increase cuts an IGBT's life in half.


9/28/2011


3/5

Figure 4

Figure 5

"Engineers at Miller developed new circuits, cooling mechanisms and other techniques so that the IGBTs are livingin luxury compared to competitive designs," says Sammons. "That's why Miller inverters lead long, stress-freelives. Also remember that Miller develops its duty cycle rating at an ambient temperature of 40 C to ensurecontinued performance in hot weather conditions."

The inverter (IGBT) portion of an inverter-based welding power source creates highoperating frequencies by switching primary electrical power on and off very rapidly.But as fast as IGBTs switch, they do not switch in zero time. If voltage and current is

flowing through the IGBT when it turns on or shuts off, its temperature increases.Previously, IGBT switching speed was limited because attempting to switch at higherfrequencies generated too much heat. While increasing the size of the IGBTs and/orheat sinks would dissipate more heat, this defeats the goal of reducing size.

Fast Switch technology minimizes heat generation by ramping the total power to zerobefore switching. This lowers the IGBT's operating temperature and enables Miller toincrease switching frequency by 40,000 Hz over its existing design. As a result ofoperating at 100,000 Hz, the transformer and inductor in the first Fast Switch productwill weigh about 1.5 lbs. each and be about the size of a golf ball (Fig. 5). Heat sinksare also smaller because of their efficient design.

Inverter Advantages

Compared to conventional power sources, inverter-based welding power sources offer the following advantages:

- Lightweight and portable

- Able to obtain superior Stick welding performance with all electrodetypes

- Multi-process welding output without sacrificing arc performance in anymode

- Quick response to changing arc conditions (e.g., maintains a steady weldoutput even if the operator's hand shakes)

- Superior control over pulsed welding processes

- Line voltage independentuses single- or three-phase input power and multiple input voltages without anymanual relinking mechanism

- Better power factor (more efficient use of power from the utility)

- Less susceptibility to primary voltage fluctuations (e.g., "dirty power")

For more information on Miller inverters, visit Miller's Web site at www.MillerWelds.com.

Technical/Informational

Welding Categories

TIGMIGMultiprocess (CC/CV)

Key Business Issues


9/28/2011


4/5

Portability

Related Articles

Smart Welding Equipment Choice...Mechanization and Inverter Wel...XMT 456 Multi-Process Invert...Multi-Process, Multi-Operator ...

View All

Article Search

Select one or all topics to refine your search.

Search By Topic:

View All Articles

RSS

Let the latest articles come to you!Subscribe to the Articles RSS Feed

What is RSS?

Follow Us:

Social Media Terms of Use


9/28/2011

Documents

Miller - New Miller Fast Switch Inverter Technology Enables Lighter, More Powerful Welding Machines