Welding Machine Final

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A Major Project Report On Electric Welding MachineSubmitted 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]

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  • 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]

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    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

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    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

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    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

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    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

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    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.

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    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

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    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

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    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

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    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

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    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

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    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

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    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

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    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

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    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

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    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

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    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

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    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)

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    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.