Control methods for arc welding power supplies

Welding is one of the most important process of modern industry. Welding technology is used in the manufacture and repair a wide variety of products from different metals and alloys. In this thesis the different aspects of arc welding were discussed, such as stability and control of welding arc, power supplies for arc welding (especially the welding inverters because it is the most modern welding power source). All parameters of power source have influence on the arc parameters and its by-turn influence on quality. The ways of control for arc welding inverter power sources have been considered. Calculations and modeling in Matlab/Simulink were done for PI control method. All parameters of power source have influence on the arc parameters and its by-turn influence on quality.

Green welding in practice

Efficient production and consumption of energy has become the top priority of national and international policies around the world. Manufacturing industries have to address the requirements of the government in relation to energy saving and ecologically sustainable products. These industries are also concerned with energy and material usage due to their rising costs. Therefore industries have to find solutions that can support environmental preservation yet maintain competitiveness in the market. Welding, a major manufacturing process, consumes a great deal of material and energy. It is a crucial process in improving a product’s life-cycle cost, strength, quality and reliability. Factors which lead to weld related inefficiencies have to be effectively managed, if industries are to meet their quality requirements and fulfil a high-volume production demand. Therefore it is important to consider some practical strategies in welding process for optimization of energy and material consumption. The main objective of this thesis is to explore the methods of minimizing the ecological footprint of the welding process and methods to effectively manage its material and energy usage in the welding process. The author has performed a critical review of the factors including improved weld power source efficiency, efficient weld techniques, newly developed weld materials, intelligent welding systems, weld safety measures and personnel training. The study lends strong support to the fact that the use of eco-friendly welding units and the quality weld joints obtained with minimum possible consumption of energy and materials should be the main directions of improvement in welding systems. The study concludes that, gradually implementing the practical strategies mentioned in this thesis would help the manufacturing industries to achieve on the following - reduced power consumption, enhanced power control and manipulation, increased deposition rate, reduced cycle time, reduced joint preparation time, reduced heat affected zones, reduced repair rates, improved joint properties, reduced post-weld operations, improved automation, improved sensing and control, avoiding hazardous conditions and reduced exposure of welder to potential hazards. These improvement can help in promotion of welding as a green manufacturing process.

On nonlinear dynamics in a free fluid surface of a tank excited by a non-ideal power source

We investigate the nonlinear oscillations in a free surface of a fluid in a cylinder tank excited by non-ideal power source, an electric motor with limited power supply. We study the possibility of parametric resonance in this system, showing that the excitation mechanism can generate chaotic response. Additionally, the dynamics of parametrically excited surface waves in the tank can reveal new characteristics of the system. The fluid-dynamic system is modeled in such way as to obtain a nonlinear differential equation system. Numerical experiments are carried out to find the regions of chaotic solutions. Simulation results are presented as phase-portrait diagrams characterizing the resonant vibrations of free fluid surface and the existence of several types of regular and chaotic attractors. We also describe the energy transfer in the interaction process between the hydrodynamic system and the electric motor. Copyright © 2011 by ASME.

Selecting an electrical power source at the scoping level for a mining project

The electrical power source is a critical component of the scoping level study as the source affects both the project economics and timeline. This paper proposes a systematic approach to selecting an electrical power source for a new mine. Orvana Minerals Copperwood project is used as a case study. The Copperwood results show that the proposed scoping level approach is consistent with the subsequent much more detailed feasibility study.

Meter data management for smart monitoring power networks

The electrical power distribution and commercialization scenario is evolving worldwide, and electricity companies, faced with the challenge of new information requirements, are demanding IT solutions to deal with the smart monitoring of power networks. Two main challenges arise from data management and smart monitoring of power networks: real-time data acquisition and big data processing over short time periods. We present a solution in the form of a system architecture that conveys real time issues and has the capacity for big data management.

Demonstration of photovoltaic power source in remote applications : lighting, weather data gathering and public demonstration systems : Wildlife Prairie Park, Peoria, Illinois.

"Printed: May 1990."

Location dependence of a MEMS electromagnetic transducer with respect to an AC power source

A MEMS, silicon based device with a cantilever oscillationsand an integrated magnet is presented for magnetic to electrical transduction. The cantilever structure can be configured either as an energy harvester to harvest power from an AC power line or as an AC current sensor. The positioning of the transducer with respect to the AC conductor is critical in both scenarios. For the energy scavenger, correct positioning is required to optimize the harvested power. For the current sensor, it is necessary to optimise the sensitivity of the sensor. This paper considers the effect of the relative position of the transducer with respect to the wire on the resulting electromagnetic forces and torques driving the device. It is shown here that the magnetic torque acting on a cantilever beam with an integrated magnet and in the vicinity of an alternating electromagnetic field is a very significant driver of the cantilever oscillations.

Hitsausvirtalähteen ohjaus lämmöntuonnin ja jatkuvan jäähtymisen S-käyrän perusteella

Lämmöntuonnilla on oleellinen vaikutus hitsausliitoksen ominaisuuksiin, koska se vaikuttaa liitoksen jäähtymisnopeuteen, jolla on puolestaan suuri vaikutus jäähtymisessä syntyviin mikrorakenteisiin. Jatkuvan jäähtymisen S-käyrältä voidaan ennustaa hitsausliitokseen syntyvät mikrorakenteet. S-käyrät voidaan laatia hitsausolosuhteiden mukaisesti, jolloin faasimuutoskäyttäytyminen sularajalla saadaan selvitettyä. Tämän diplomityön tavoitteena oli kehittää hitsausvirtalähteen ohjaustapaa lämmöntuontiin ja jatkuvan jäähtymisen S-käyriin perustuen. Jatkuvan jäähtymisen S-käyrillä ja lämmöntuontiin perustuvalla hitsausparametrien säädöllä on yhteys. Työssä tutkittiin, miten haluttuun jäähtymisnopeuteen johtava lämmöntuonti voidaan määrittää S-käyrälle luotettavasti. Työssä perehdyttiin jatkuvan jäähtymisen S-käyriin ja eri jäähtymisnopeuksilla hitsausliitokseen syntyviin mikrorakenteisiin sekä hitsaus-inverttereiden ohjaus- ja säätötekniikkaan. Teoriaosuuden jälkeen tarkasteltiin eri vaihtoehtoja, miten hitsattavan materiaalin koostumusvaihtelut sekä lämmöntuontiin vaikuttavat tekijät voidaan ottaa huomioon virtalähteen ohjauksessa lämmöntuonnin perusteella. S-käyrältä määritettyjen lämmöntuonnin arvojen perusteella tehtiin kahdet koehitsaukset, joissa käytettiin kolmea eri aineenpaksuutta. Tulosten perusteella arvioitiin lämmöntuonnin arvojen toimivuutta käytännössä ja tutkittiin liitokseen syntyviä mikrorakenteita. Tutkimuksen pohjalta esitettiin jatkokehitystoimenpiteitä, joiden mukaan voidaan edetä lämmöntuontiin perustuvan säätöjärjestelmän kehitysprojektissa.

Ultra-Low Power and Non-intrusive Wireless Monitoring for Smart Buildings

Wireless Sensor Networks (WSNs) offer a new solution for distributed monitoring, processing and communication. First of all, the stringent energy constraints to which sensing nodes are typically subjected. WSNs are often battery powered and placed where it is not possible to recharge or replace batteries. Energy can be harvested from the external environment but it is a limited resource that must be used efficiently. Energy efficiency is a key requirement for a credible WSNs design. From the power source's perspective, aggressive energy management techniques remain the most effective way to prolong the lifetime of a WSN. A new adaptive algorithm will be presented, which minimizes the consumption of wireless sensor nodes in sleep mode, when the power source has to be regulated using DC-DC converters. Another important aspect addressed is the time synchronisation in WSNs. WSNs are used for real-world applications where physical time plays an important role. An innovative low-overhead synchronisation approach will be presented, based on a Temperature Compensation Algorithm (TCA). The last aspect addressed is related to self-powered WSNs with Energy Harvesting (EH) solutions. Wireless sensor nodes with EH require some form of energy storage, which enables systems to continue operating during periods of insufficient environmental energy. However, the size of the energy storage strongly restricts the use of WSNs with EH in real-world applications. A new approach will be presented, which enables computation to be sustained during intermittent power supply. The discussed approaches will be used for real-world WSN applications. The first presented scenario is related to the experience gathered during an European Project (3ENCULT Project), regarding the design and implementation of an innovative network for monitoring heritage buildings. The second scenario is related to the experience with Telecom Italia, regarding the design of smart energy meters for monitoring the usage of household's appliances.

Operation modes for the electric vehicle in smart grids and smart homes : present and proposed modes

This paper presents the main operation modes for an electric vehicle (EV) battery charger framed in smart grids and smart homes, i.e., are discussed the present-day and are proposed new operation modes that can represent an asset towards EV adoption. Besides the well-known grid to vehicle (G2V) and vehicle to grid (V2G), this paper proposes two new operation modes: Home-to-vehicle (H2V), where the EV battery charger current is controlled according to the current consumption of the electrical appliances of the home (this operation mode is combined with the G2V and V2G); Vehicle-for-grid (V4G), where the EV battery charger is used for compensating current harmonics or reactive power, simultaneously with the G2V and V2G operation modes. The vehicle-to-home (V2H) operation mode, where the EV can operate as a power source in isolated systems or as an off-line uninterruptible power supply to feed priority appliances of the home during power outages of the electrical grid is presented in this paper framed with the other operation modes. These five operation modes were validated through experimental results using a developed 3.6 kW bidirectional EV battery charger prototype, which was specially designed for these operation modes. The paper describes the developed EV battery charger prototype, detailing the power theory and the voltage and current control strategies used in the control system. The paper presents experimental results for the various operation modes, both in steady-state and during transients.

Welding development of crane main girder

Konecranes Corporation manufactures huge steel structures in 16 factories worldwide, in which the environment and quality varies. The company has a desire to achieve the same weld quality in each factory, regardless of the manufacturing place. The main subject of this master’s thesis was to develop the present box girder crane welding process, submerged arc welding and especially the fillet welding. Throughput time and manufacturing costs can be decreased by welding the full penetration fillet weld without a bevel, changing present groove types for more appropriate ones and by achieving the desired weld quality on the first time. Welding experiments of longitudinal fillet welding were made according to the present challenges, which the manufacturing process is facing. In longitudinal fillet welding tests the main focus was to achieve full penetration fillet weld for 6, 8 and 10 millimeters thick web plates with single and twin wire submerged arc welding. Full penetration was achieved with all the material thicknesses, both with single and twin wire submerged arc welding processes. The main problem concerning the weld was undercutting and shape of the weld bead. The question about insufficiency of presently used power sources with twin wire was risen up during testing, due to the thicknesses that require high welding current. Bigger power source is required when box girders are welded nonstop, if twin wire is used. For single wire process the penetration was achieved with significantly less amperage than with twin wire.

Power quality, smart meters and additional information from different power terms

This paper shows how the detailed examination of active and nonactive power components may produce new information for modern smart meters. For this purpose, a prototype of electronic power meter has been implemented and applied to the evaluation of the Conservative Power Theory (CPT). Considering five sorts of loads, under four different operating conditions, the experimental results indicate that the CPT is able to provide a good methodology for load characterization, which could possibly benefits consumers and power utilities in several different ways. The results also show that depending on the situation, the analysis of nonactive power terms may be more important than the observation of traditional power quality indices, such as total harmonic distortion, unbalance factors or the fundamental positive sequence power factor.

DESIGN AND IMPLEMENTATION OF HOME USE PORTABLE SMART ELECTRONICS

The widespread of low cost embedded electronics makes it easier to implement the smart devices that can understand either the environment or the user behaviors. The main object of this project is to design and implement home use portable smart electronics, including the portable monitoring device for home and office security and the portable 3D mouse for convenient use. Both devices in this project use the MPU6050 which contains a 3 axis accelerometer and a 3 axis gyroscope to sense the inertial motion of the door or the human hands movement. For the portable monitoring device for home and office security, MPU6050 is used to sense the door (either home front door or cabinet door) movement through the gyroscope, and Raspberry Pi is then used to process the data it receives from MPU6050, if the data value exceeds the preset threshold, Raspberry Pi would control the USB Webcam to take a picture and then send out an alert email with the picture to the user. The advantage of this device is that it is a small size portable stand-alone device with its own power source, it is easy to implement, really cheap for residential use, and energy efficient with instantaneous alert. For the 3D mouse, the MPU6050 would use both the accelerometer and gyroscope to sense user hands movement, the data are processed by MSP430G2553 through a digital smooth filter and a complementary filter, and then the filtered data will pass to the personal computer through the serial COM port. By applying the cursor movement equation in the PC driver, this device can work great as a mouse with acceptable accuracy. Compared to the normal optical mouse we are using, this mouse does not need any working surface, with the use of the smooth and complementary filter, it has certain accuracy for normal use, and it is easy to be extended to a portable mouse as small as a finger ring.

Survey of alternating-current power supplies for welding /

"November 1964."

Development and Verification of Control and Protection Strategies in Hybrid AC/DC Power Systems for Smart Grid Applications

Modern power networks incorporate communications and information technology infrastructure into the electrical power system to create a smart grid in terms of control and operation. The smart grid enables real-time communication and control between consumers and utility companies allowing suppliers to optimize energy usage based on price preference and system technical issues. The smart grid design aims to provide overall power system monitoring, create protection and control strategies to maintain system performance, stability and security. This dissertation contributed to the development of a unique and novel smart grid test-bed laboratory with integrated monitoring, protection and control systems. This test-bed was used as a platform to test the smart grid operational ideas developed here. The implementation of this system in the real-time software creates an environment for studying, implementing and verifying novel control and protection schemes developed in this dissertation. Phasor measurement techniques were developed using the available Data Acquisition (DAQ) devices in order to monitor all points in the power system in real time. This provides a practical view of system parameter changes, system abnormal conditions and its stability and security information system. These developments provide valuable measurements for technical power system operators in the energy control centers. Phasor Measurement technology is an excellent solution for improving system planning, operation and energy trading in addition to enabling advanced applications in Wide Area Monitoring, Protection and Control (WAMPAC). Moreover, a virtual protection system was developed and implemented in the smart grid laboratory with integrated functionality for wide area applications. Experiments and procedures were developed in the system in order to detect the system abnormal conditions and apply proper remedies to heal the system. A design for DC microgrid was developed to integrate it to the AC system with appropriate control capability. This system represents realistic hybrid AC/DC microgrids connectivity to the AC side to study the use of such architecture in system operation to help remedy system abnormal conditions. In addition, this dissertation explored the challenges and feasibility of the implementation of real-time system analysis features in order to monitor the system security and stability measures. These indices are measured experimentally during the operation of the developed hybrid AC/DC microgrids. Furthermore, a real-time optimal power flow system was implemented to optimally manage the power sharing between AC generators and DC side resources. A study relating to real-time energy management algorithm in hybrid microgrids was performed to evaluate the effects of using energy storage resources and their use in mitigating heavy load impacts on system stability and operational security.