TABLE OF CONTENTS
COVER PAGE
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWLEDGMENT
ABSTRACT
TABLE OF CONTENTS
CHAPTER ONE
1.0 INTRODUCTION
1.1 BACKGROUND OF THE PROJECT
1.2 AIM/OBJECTIVE OF THE PROJECT
1.3 SIGNIFICANCE OF THE PROJECT
1.4 SCOPE OF THE PROJECT
1.5 PURPOSE OF THE PROJECT
1.6 LIMITATION OF THE PROJECT
1.7 APPLICATION OF THE PROJECT
1.8 PROBLEMS OF THE PROJECT
1.9 PROJECT ORGANISATION
CHAPTER TWO
2.0 LITERATURE REVIEW
- HISTORICAL BACKGROUND OF THE PROJECT
- TRANSFORMER DESIGN
- REVIEW OF TYPES OF ARC WELDING ELECTRODE METHODS
- REVIEW OF WELDING EQUIPMENT
- FACTORS AFFECT WELD QUALITY
- REVIEW OF SYSTEM MICROCONTROLLER
CHAPTER THREE
3.0 CONSTRUCTION METHODOLOGY
- BLOCK DIAGRAM
- DESCRIPTION OF SYSTEM BLOCK
- BASIC PRINCIPLE OF ARC WELDING MACHINE
- THEORY AND DESIGN OF WELDING TRANSFORMERS
- SYSTEM OPERATION
- DESIGN CALCULATION
- COST ANALYSIS
CHAPTER FOUR
4.0 RESULT ANALYSIS
- CONSTRUCTION PROCEDURE
- CASING AND PACKAGING
- ASSEMBLING SECTION
- SYSTEM TESTING
- DESIGN PRECAUTION
CHAPTER FIVE
- CONCLUSION AND RECOMMENDATION
- CONCLUSION
- RECOMMENDATION
- REFERENCES
CHAPTER ONE
1.0 INTRODUCTION
An Arc welding machine is a type of welding machine 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. The arc welding is a fusion welding process in which the welding heat is obtained from an electric arc struck between the work(or base metal) and an electrode.
They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. First developed in the late part of the 19th century, arc welding became commercially important in shipbuilding during the Second World War. Today it remains an important process for the fabrication of steel structures and vehicles.
Arc welding machine has Main cable that receives energy from the source (220 or 440 Volts AC), the starter or switch, the transformer, the controls of tension (Voltage) and current (Amps-or-Amperage), the two secondary wires: one is to ground the machine to the building + structure + part that you are to weld, the other is to put your electrode and produce the welding
The direction of current used in arc welding also plays an important role in welding. Consumable electrode processes such as shielded metal arc welding and gas metal arc welding generally use direct current, but the electrode can be charged either positively or negatively. In welding, the positively charged anode will have a greater heat concentration and, as a result, changing the polarity of the electrode has an impact on weld properties. If the electrode is positively charged, it will melt more quickly, increasing weld penetration and welding speed. Alternatively, a negatively charged electrode results in more shallow welds. Non-consumable electrode processes, such as gas tungsten arc welding, can use either type of direct current (DC), as well as alternating current (AC). With direct current however, because the electrode only creates the arc and does not provide filler material, a positively charged electrode causes shallow welds, while a negatively charged electrode makes deeper welds. Alternating current rapidly moves between these two, resulting in medium-penetration welds. One disadvantage of AC, the fact that the arc must be re-ignited after every zero crossing, has been addressed with the invention of special power units that produce a square wave pattern instead of the normal sine wave, eliminating low-voltage time after the zero crossings and minimizing the effects of the problem.
At the end of the work an electric arc welding is been built with a power source of 230 VAC. The machine is monitored continuously by the microprocessor which manages the welding process in real time: all the parameters are processed and modified immediately, in a few microseconds, by the control that digitally manages the short circuits that are typical of MIG-MAG welding, keeping the arc stable and precise in spite of any change of the external conditions. This way, torch movement, irregularities of parts to be welded and other factors do not influence the final result at all. Welding process is always under control from arc striking, by Wire Start Control (WSC), to when the arc is interrupted by Burn Back Control.
The LCD used is 16x2 LCD. 16x2 LCD means it can display 16 characters per line and there are 2 such lines. In this LCD each character is displayed in 5x7 pixel matrix. This LCD has two registers, namely, Command and Data.
1.1 AIM AND OBJECTIVE OF THE PROJECT
The aim of this work is to design and construct a digital arc welding machine. To design and construct an electric machine that will create an electric arc between an electrode and the base material to melt the metals at the welding point with an LCD display which displays the ambient temperature of the device.
1.2 PURPOSE OF THE PROJECT
The purpose of his work is to design a welding machine that creates an electric arc between an electrode and the base material to melt the metals at the welding point. This machine has the ability to display the ambient temperature during working time and idle time.
1.3 SIGNIFICANCE OF THE PROJECT
a. AC Arc Welding Transformers are extensively used today in machine building and general purpose maintenance and fabrication work. Light medium and heavy structural work as a Power Source.
b. The safety advantages of switching to welding machine include reduced health hazards for workers. From limiting exposure to hazardous fumes to decreased risk of arc burn, arc welding machine help to save workers from a once dangerous job.
c. It has high welding efficiency and speed.
d. It provides better welding environment.
e. It gives consistent quality of weld.
f. It forms the strong bond in between the joined metals.
g. It has simple welding equipment.
h. Power source is not so expensive.
i. It is fast and reliable process.
j. Equipments can be used for multiple functions.
k. Welders can use standard domestic current.
1.4 LIMITATION OF THE PROJECT
1) Higher initial setup cost because of the display and the microcontroller used.
2) Atmosphere surrounding the welding process has to be stable therefore this process is limited to draught free conditions
3) Higher maintenance costs due to extra electronic components
4) The setting of plant variables requires a high skill level
5) Less efficient where high duty cycle requirements are necessary
6) Radiation effects are more severe
1.5 BENEFIT OF THE PROJECT
This microcontroller based arc welding machine uses a process which applies intense heat to metal at a joint, causing the metal to melt and intermix. Arc welding machine has several benefits, including improved weld consistency, decreased cycle times, and enhanced efficiency.
1.6 APPLICATION OF THE PROJECT
Arc welding utilizes an electric arc between an electrode and a metal base using either consumable or non consumable electrodes. This welding machine is commonly found in steel product and automobile manufacturing. Other applications include:
- Welding of thin thickness laminations with low heat transfer
- Open gap joints in all positions
- MIG brazing with low heat transfer
- Welding of stainless steel
- Light and medium fabrication work
- Manufacture of mild and stainless steel and aluminium
- Automotive industry
- Petrochemical industry
- Food industry
- Railway wagon manufacturing
- Small medium size tank and container construction
1.7 PROBLEM OF THE PROJECT
High skilled operator is required to do arc welding and also heavy to carry because of the iron cores and copper wires.
1.8 PROJECT WORK ORGANISATION
The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:
Chapter one of this work is on the introduction to the study. In this chapter, the background, significance, objective, purpose, application, limitation and problem of the study were discussed.
Chapter two is on literature review of this study. In this chapter, all the literature pertaining to this work was reviewed.
Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.
Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.
Chapter five is on conclusion, recommendation and references.
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