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Construction Of Welding Machine
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CHAPTER FOUR
4.0 DESIGN CALCULATION
For every machine in engineering field, there must be proof mathematically on which the machine is designed to ensure reproducibility, improvisation and customization and mainly varies design to meet specific purpose.
The following assumption were adapted before proceeding to the calculation.
That the flux leakage is negligible
That there is a constant magnetizing current wave
The equipment should be low voltage high current at secondary side
The working frequency is 50Hz.
The design values used in this project are:
Output current 180A (for continuous operation)
Rating of transformer 8kvA
Et = induced potential in the welding
Lamination thickness number of turns
Et = F square roots (Et = √F
Where S = transformer rating in kvA
K = Volts per turn factor given as 0.35
Et = 0.35 sqaure root and 0.99v
Ep = 240v = primary voltage
Np = primary welding
Np = Ep ………………….(i) (Giancoli Douglas C. (1998)]
Et
= 240v = 240.42
0.99v
To get the primary welding current lp
S = p = lp Ep Cos Ø = machine power rating……………. (ii) [ulaby fawwaz (2007]
Where Cos Ø is the power factor given as 0.8
8kvA = lp x 240 x 0.8
lp = 800vA = 44. 66A
240 x 0.8
lp = 45A primary current
from faraday low
Ep Np Ep lp Ns Es………………(i) [Joseph henry (2006]
15 Np E3 lp Np Ep
240 = 180
Ns 45
Ns = 240 x 45 = 60 secondary turns
180
Also = Np = Ep …………………………….(ii) [Michael day p(1999]
Es = 60 x 240
240
Es = 60 secondary voltage (potential)
From above the calculated values are
Number of turns
Secondary windings = 60 turns =Ns
Primary windings = 240 turns
Current rating winding
Primary current = 45A
Secondary current = 180 A
Potential level
Primary Potential = 240 volts
Secondary potential = 60 volts
The number of turns in the other current tapping is calculated as follows with corresponding value of current.
For 150 A (I)
Fi = I
N p = I ………………………………… (iii) [pearce Williams P. 191 5]
Ni lp
N1 = 240 x 45 = 72turns
150
For 120A (12)
Np = 12
N2 = lp
= 240 x 4 = 90 turn
120
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ABSRACT - [ Total Page(s): 1 ]ABSTRACT COMING SOON ... Continue reading---
CHAPTER ONE - [ Total Page(s): 2 ]CHAPTER ONE1.0 INTRODUCTIONIn the past with the necessary of metals it always seems impossible to join two metals together with grooving riveting, this idea leads to alternative of finding a lasting solution to the problem. This brought about the idea of a welding machine with a well laminated core and coil wound together to form a high rated transformer which is immersed in a can of oil.Welding is the most economical and efficient way to join metals permanently. It is the only way of join ... Continue reading---
CHAPTER TWO - [ Total Page(s): 3 ]ii. OXIDIZING FLAMEOxidizing welding flame are produced hen slightly more than one volume of oxygen is mixed with one volume of acetylene. To obtained this type of flame, the flow of oxygen is then increased until the inner cone is shortened to about one tenth of it original length when the flame is properly adjusted, the inner cone is pointed and slightly purple. An oxidizing flame can also be recognized by it distinct hissing sound. The temperature of this flame is approximately 6300oF ( ... Continue reading---
CHAPTER FOUR - [ Total Page(s): 4 ]Where;K = constant (Boltzman constant in joules / kelvin)A= 200m x 4 = 800mmT2 = 3500CT1 = 3150CX = 50mmQ = k x 800mm 350 – 3150C 50mm Where K =8.617 x 10-5 J/kQ = 8.673 x 10-5 x 800mm (135 50mmQ =62044.46 J/K 4.1 WINDING DESIGNThe
basic of winding is to have number of turns being wounded around an
appropriate point of the core. Winding design in transformer
construction must be done perfectly and accura ... Continue reading---
CHAPTER FIVE - [ Total Page(s): 10 ]Now let assume a load having a power factor such that the secondary current is in phase with E2 the primary current must now have two component.1. I1 to maintain the useful flux2. I2 to neutralize the demagnetizing effect of the secondary current.Since the flux of each limb is link only with the winding by which it is produced, it is referred to as leakage flux and its responsible for reducing an e.m.f. of self inductance in the winding with which it is linked. The reluctance o ... Continue reading---
CHAPTER SIX - [ Total Page(s): 1 ]CHAPTER SIX6.0. CONCLUSION AND RECOMMENDATION6.1 CONCLUSION The project is a form of providing student with appreciable skills p4actically designed to expose or equip them with real working operation of machine and how they are being constructed and a better understanding of one’s own career goals and for the progress of the nation.The project seemed easy and simple but later on turn to be useful and interesting project for Engineering students. With all the proble ... Continue reading---
REFRENCES - [ Total Page(s): 1 ]REFERENCESFlood CR (1981) “Fabrication of welding and joining process†1st Edition, Butterworth and Co publisher limited London, P.P 21 – 25, 28 36- 37 and 39.Google: http://weldguru.com/welding-flamesFlood CR and parkin N. (1974) “craft practice “ 1st Edition pergamon press limited, New YorkDavies A.C (1984) “Welding science and technology†8th edition Cambridge Universities press. London Pg-42B.L. and A.K.Therage (1994 Textbook of Electri ... Continue reading---
