Magnetic Saturation Suppression of Intermediate Frequency DC Resistance Spot Welding Power Supply

The manufacturing process and the consistency of rectifier diodes on the secondary side can significantly impact the performance of the intermediate frequency (IF) transformer in resistance spot welding (RSW) power supplies. In high current welding applications, the IF transformer may experience magnetic saturation, leading to a rapid decrease in the inductance of the primary side winding. This can result in a sharp increase in primary side current, potentially causing damage to the inverter bridge and transformer of the power supply, and ultimately reducing the overall equipment reliability. This study focuses on the analysis of transformer magnetic saturation in spot welding power systems. A strategy is proposed to mitigate transformer magnetic saturation through secondary current compensation for IF DC spot welding inverter power supplies. The effectiveness and feasibility of this approach are evaluated through simulation and experimental validation, demonstrating its potential to enhance the performance and reliability of the welding equipment.