A
Major Project Report
On
Electric Welding Machine
Submitted
in partial fulfillment
for the award of the Degree of
Bachelor of Technology
In
Electrical Engineering
Submitted To: Submitted By:
Mr.Deepak Sharma Rupesh Kumar
Head of Department Srijan Tripathi
Jitesh Tripathi
Department of Electrical Engineering
AryaCollege of Engineering &Research Centre, Jaipur
Rajasthan Technical University, Kota
[2011-15]
ACERC/DOEE/2014-15/PROJECT/I
ARYA COLLEGE OF ENGINEERING &RESEARCH CENTRE SP-40, RIICO Industrial Area, Jaipur (Raj)-302022
Department of Electrical Engineering
Certificate
This is to certify that the work, which is being presented in the project
report for Major Project on Electric Welding Machine, submitted by
Mr. Srijan Tripathi, Mr. Rupesh Kumar, Mr. Jitesh Kumar a student of
fourth year (VIII Sem) B.Tech. in Electrical Engineering as a partial
fulfillment for the award of degree of Bachelor of Technology is a
record of students work carried out and found satisfactory for
submission.
Mr. Rajat Sahu Mr.DeepakSharma Project Coordinator Head of Department
ACERC/DOEE/2014-15/PROJECT/II
Candidates Declaration
I hereby declare that the work, which is being presented in the project, entitled Electric
Welding Machine in partial fulfillment for the award of Degree of Bachelor of
Technology in Electrical Engineering, submitted to the Department of Electrical
Engineering, Arya College of Engineering &Research Centre, Rajasthan Technical University
is a record of my own work carried under the Guidance of Mr. Deepak Sharma.
I have not submitted the matter presented in this Report anywhere for the award of any other
Degree.
(Signature of Candidates)
SRIJAN TRIPATHI
RUPESH KUMAR
JITESH KUMAR
ACERC/DOEE/2014-15/PROJECT/III
ACKNOWLEDGEMENT
We wish to express our deep sense of gratitude to our Guide Mr. Rajat Sahu. For guiding me
from the inception till the completion of the Project. We sincerely acknowledge him for giving his
valuable guidance, support for literature survey, critical reviews and comments for our Project.
We would like to first of all express our thanks to Dr. Pooja Agarwal, Director of Arya Main
Campus,for providing us such a great infrastructure and environment for our overall development.
We express sincere thanks to Prof(Dr.)I C Sharma the Principal of ACERC, for his kind
cooperation and extendible support towards the completion of our project.
Words are inadequate in offering our thanks to Mr. Deepak Sharma, H.O.D of EE Department,
for consistent encouragement and support for shaping our project in the presentable form.
We also express our deepest thanks to Mr. Deepak Sharma for his support in providing technical
requirement and fulfilling our various other requirements for making our project success.
We also like to express our thanks to all supporting EE faculty members who have been a constant
source of encouragement for successful completion of the project.
Also our warm thanks to Arya College of Engineering &Research Centre, who provided us this
opportunity to carryout, this prestigious Project and enhance our learning in various technical
fields.
Srijan Tripathi
Rupesh Kumar
Jitesh Kumar
ACERC/DOEE/2014-15/PROJECT/IV
ABSTRACT
This project presents the development, utilization and application of electric arc
welding machine (Single phase). Arc welding is a type of welding that uses a welding
power supply to create an electric arc between an electrode and the base material to melt
the metals at the welding point. This electric arc welding machine was designed and
constructed using locally available materials.
And we have made a welding transfer of core size of 9 height and 9 length and
2 breadth. The core has square shape. We used four winding coil in a transformer in
which two winding coil for primary side and two for secondary side. The primary side coil
is made of aluminium DCC conductor of size 10SWG with four tapping on each winding
in a particular interval of turns and in secondary side we use a 4SWG DCC conductor wire
to make a coil.
This welding machine is capable of weld a metal by using different types of
welding rod like 8, 10 and 12 number, by changing a tapping of the primary side of
winding.
Our welding machine is light weight and easily movable from one place to another
place. This welding machine can be used in small scale industries and small light weight
works
ACERC/DOEE/2014-15/PROJECT/V
LIST OF FIGURES
FIG 1.1 ARC WELDING MACHINE 1
FIG 3.1 CORE OF TRANSFORMER (TOP VIEW) 3
FIG 3.2 FRONT VEW OF CORE 4
FIG 3.3 PRIMARY COIL FIXED ON A CORE 5
FIG 3.4 SECONDARY WINDING FIXED ON A CORE 6
FIG 4.1 SERIES CONNECTION OF TRANSFORMER 7
FIG 4.2 FINAL VIEW OF CONNECTION 7
FIG. NO. FIGURE NAME PAGE NO.
ACERC/DOEE/2014-15/PROJECT/VI
CONTENTS
CERTIFICATE FROM DEPARTMENT I
CANDIDATES DECLARATION II
ACKNOWLEDGEMENT III
ABSTRACT IV
FIGURE LIST V
TABLE LIST VI
CHAPTER 1 ARC WELDER 1
1.1 INTRODUCTION 1
CHAPTER 2 MATERIAL REQUIRED 2
2.1 MATERIAL AND QUANTITY 2
CHAPTER 3 CONSTRUCTION AND DESIGN 3-6
3.1 CORE 3
3.2 COILS CONSTRUCTION 4
CHAPTER 4 CONNECTIONS 7
CHAPTER 5 SPECIFICATIONS AND COST 8
5.1 DESCRIPTION 8
5.2 COST 8
CHAPTER 6 SURVEY 9-10
6.1 TRANSFORMER INDUSTRIES IN JAIPUR 9
6.2 WELDING TRANSFORMER DEALER IN JAIPUR 9
6.3 RATE LIST 9
6.4 COMPARATIVE ANALYSIS 10
CHAPTER 7 ADVANTAGE AND DISADVANTAGE 11
7.1 ADVANTAGES 11
7.2 DISADVANTAGES 11
CONCLUSION 12
ACERC/DOEE/2014-15/PROJECT/1
CHAPTER 1
ARC WELDER
1.1 INTRODUCTION
This is a transformer type arc welder that will transform incoming high voltage, low amperage
electricity into high amperage, low voltage welding current. An arc welder should be on a separate
circuit of its own with a 50 amp. Breaker and in our welding transformer it will take from power
supply 220volt and 3 amps no load current and it give output of 200 amp range current and 40 volt
at output terminals. And it melts the 8 no. rod to weld any metallic surface. The diagram of the
transformer is shown as below.
FIGURE1.1: ARC WELDING MACHINE
ACERC/DOEE/2014-15/PROJECT/2
CHAPTER 2
MATERIAL REQUIRED
MATERIAL QUANTITY
1. TRANSFORMER CORE SIZE (9 X 2 & 5 X 2)
2. WINDING CONDUCTOR SWG (10 & 4)
3. INSULATING PAPER CLASS B
4. COTTON TAPE 1 INCH
5. PVC TAPE 1
6. SLIP 4
7. NUTS AND BOLTS 16
8. VARNISH 500 ML
9. BAKELITE SHEET 12 INCHES
10. LUX 4
11. INDICATOR 1
12. HOLDER 1
13. HOLDER LEAD 10 MM (2 METERS)
14. PVC CABLE 6 MM (3 METERS)
15. WELDING RODS 8, 10&12 NUMBERS
16. CLAMPS 4(12 X 2)
17. PLIER 1
18. CUTTER 1
19. SCREW DRIVER 1
20. WRIENCH 2(10-12, 14-15)
21. HAMMER 1( 200 GRAMS)
22. SCISSOR 1
23. CLAMP METER 1
ACERC/DOEE/2014-15/PROJECT/3
CHAPTER 3
CONSTRUCTION AND DESIGN OF WELDING
TRANSFORMER
3.1. CORE
The performance of a transformer mainly depends upon the flux linkages between the
windings. For efficient flux linking between the windings, one low reluctance magnetic
path common to all windings should be provided in the transformer. This low reluctance
magnetic path in transformer is known as core of transformer.
We used an insulated metal strip (CRGO) of size 92 and 52 for a construction of a core
of a transformer. The size of the core of transformer is 9 of length and 9 inches of
breadth. The weight of a whole transformer core is 14.5 kg. The construction of core is
shown in the figure 2.1 below.
FIGURE 3.1: CORE OF TRANSFORMER (TOP VIEW)
In this we made a core type construction for a transformer, in which we placed two coils in
each of the vertical leg of the core. When these lamination stampings is connected together
ACERC/DOEE/2014-15/PROJECT/4
form the required core shape as shown in above figure2.1 and their side view of core also
shown in the figure2.2.
FIGURE 3.2: FRONT VEW OF CORE
3.2 COILS CONSTRUCTION
The conducting material used for the windings depends upon the application, but in all
cases the individual turns must be electrically insulated from each other to ensure that the
current travels throughout every turn. The coils used for this transformer are form-wound
and are of cylindrical type. The cylindrical coils will have different layers and each layer
will be insulated from the other with the help of materials like paper, cloth, etc.
2.2.1. Primary winding:
The transformer's primary winding creates a varying magnetic flux in the core and a
varying magnetic field affect on the secondary winding. This varying magnetic field at the
secondary induces a varying electromotive force (EMF) or voltage in the
secondary winding.
For the construction of primary winding coil DCC conductor is used, which come in
different size. For the primary coil we use 2.4 kilograms of 10 SWG aluminium DCC
ACERC/DOEE/2014-15/PROJECT/5
conductors. The coil made by wrapping the conductors in a cylindrical form layer by layer.
Paper is used to insulate the different layers of the coil.
In the primary winding coil there is 125 numbers of turns in each coil.there are fours
tapping is available in primary coil in every 24 turns.
No. of turns in primary coil each, N1 =125
FIGURE 3.3. PRIMARY COIL FIXED ON A CORE
3.2.2. Secondary Winding
The secondary winding that provides the output to the load or loads. The flux, produced by
primary winding, passes through the core, will link with the secondary winding. The same
ACERC/DOEE/2014-15/PROJECT/6
aluminium DCC conductor used in primary winding coil Is also used in secondary winding
coil. But size of the conductor for secondary winding is different. We use 2.4 kilograms of
4 SWG alluminium DCC conductors for secondary side coil. We made two coils for
secondary side of transformer. The each coil having a 38 number of turns.
No. of turns in secondary coil each, N2=38
FIGURE 3.4 SECONDARY WINDING FIXED ON A CORE
ACERC/DOEE/2014-15/PROJECT/7
CHAPTER 4
CONNECTIONS
The connection of the welding transformer done in series connection. The coil is arranged
over the core in alternate form. In the first leg placed primary coil, then the secondary coil.
Similarly on the another leg put secondary coil first then primary coil over the secondary.
These coil insulated from each by using a insulated paper.
FIGURE 4.1: SERIES CONNECTION OF TRANSFORMER
FIGURE 4.2: FINAL VIEW OF CONNECTION
ACERC/DOEE/2014-15/PROJECT/8
CHAPTER 5
SPECIFICATIONS AND COST
5.1DESCRIPTION:
180 amp air cooled arc welder.
1) Input voltage / phase: 220 volt / 1
2) Current input: 3 amps 27 amps
3) Current output: 70 amps 180 amps
4) Voltage output: 20.8 volt 25.2 volt
5) Welding rods recommended: 1 mm 3 mm
6) Dimensions (Length X Breadth X Height) : 14 X 12 X 14.
7) Weight: 20KG.
5.2 COST
MATERIAL COST (RS.)
CORE - 1200
CONDUCTOR - 1500
ELECTRODE HOLDER - 200
HOLDER LEAD - 260
PVC CABLE - 50
BAKELITE SHEET - 60
VARNISH AND PAPER - 250
COTTON TAPE - 140
LUX - 40
OTHERS - 500
TOTAL COST - 4200
ACERC/DOEE/2014-15/PROJECT/9
CHAPTER 6
SURVEY
6.1. TRANSFORMER INDUSTRIES IN JAIPUR
1. Uttam Bharat Electricals Private Limited
Road no. 9F, V.K.I Industrial Area Jaipur Rajasthan
2. Indian Transformer Electrical
Road no. 17, V.K.I Industrial Area, Jaipur, Rajasthan.
3.Shree Transformers
V.K.I Area, Jaipur, Rajasthan
4. Swastik Copper Private Limited
Sitapura Jaipur,Rajasthan
6.2. WELDING TRANSFORMER DEALER IN JAIPUR
1. Anil Electrical,
M.I Road, Jaipur ,Rajasthan.
2. Maheshwari Electrical
Mi Road, Jaipur, Rajasthan
3. Avishkar Traders
Shansar Chand Road, Jaipur, Rajasthan.
6.3. RATE LIST
s. no. Brand name Type rating Cost(Rs.)
1. Primeir 4 coil 50-200amp 5500
2. Hi-tech 4 coil 70-250amp 6200
3. Vulcan 4 coil 55-200amp 5800
ACERC/DOEE/2014-15/PROJECT/10
6.4. COMPARATIVE ANALYSIS
Brand Primeir Hi-tech Vulcan Our welding
machine
Type 4-coil 4-coil 4-coil 4-coil
Rating(amps) 50-200 70-250 55-200 70-200
Cost(Rs.) 5500 6200 5800 4200
ACERC/DOEE/2014-15/PROJECT/11
CHAPTER 7
ADVANTAGE AND DISADVANTAGE
7.1. ADVANTAGES
Versatility - readily applied to a variety of applications and a wide choice of
electrodes
Relative simplicity and portability of equipment
Low cost
Adaptable to confined spaces and remote locations
Suitable for out-of-position welding
7.2. DISADVANTAGES
Not as productive as continuous wire processes
Likely to be more costly to deposit a given quantity of metal
Frequent stop/starts to change electrode
Relatively high metal wastage (electrode stubs)
Current limits are lower than for continuous or automatic processes (reduces
deposition rate)
ACERC/DOEE/2014-15/PROJECT/12
CONCLUSION
Welding is a fabrication process that joins materials; usually metals. This is often done by
melting the work-piece and adding a filler material to form a pool of molten material (the
weld pool) that cools become a strong joint. The melting is achieved with pressure
sometimes used in conjunction with heat, to produce the weld. Different power supply can
be used for welding. Arc welding machine transform low voltage low amperage primary
power into the low voltage, high amperage power used for welding at high frequency. This
high frequency transformation helps to reduce the weight and size of the transformer.
The samples were characterized by means of tensile strength, hardness and elongation.
From the investigation it is found that an increase in welding speed increases the tensile
strength and increase in tool rotation speed, decreases the tensile strength.
Welding means the permanent joining together of components by means of heat or
pressure, with or without welding additives. It has specialized in arc welding, one of the
oldest electrical welding processes for metallic materials. This arc between a consumable
electrode as additive material and the work piece, functions as a heat source when welding.