An inverter welder uses solid-state rectifiers and switches to convert AC input power to DC output power, controlled by computer software. It is smaller, lighter, and more energy-efficient than traditional welding power supplies, with a higher frequency output current for consistent welding. It can power all welding processes and is popular in maintenance, repair, and fabrication shops, as well as for on-the-spot repairs by farmers.
An inverter welder is a type of welding power supply that can supply a high current for welding. The welder uses a series of solid-state rectifiers and switches to convert alternating current (AC) input power at 60 Hz to direct current (DC) output power. The amount of output current and voltage available during the welding process is controlled by the computer software. An inverter welding machine weighs significantly less and at the same time consumes less electricity than a comparable conventional welding power supply.
A traditional welding power supply uses a large iron core transformer to convert low amperage, high voltage AC to high amperage, low voltage AC. A rectifier is then used to convert the alternating current to direct current for use in the welding process. The transformer in this type of power typically needs to be large enough to function properly.
An inverter welder first uses a rectifier to convert the incoming AC to DC. This current turns on and off very rapidly, creating a high-frequency pulsed direct current. Typical frequencies range from 10,000 to 20,000 Hz, although frequencies as high as 100,000 Hz are possible. The high frequency, low amperage current is fed into a transformer where it is transformed into high amperage direct current, before being rectified again.
These have several advantages over a traditional welding power supply. Both require a transformer to convert the input current into suitable welding current, although with an inverter welder this can be done more efficiently at higher frequencies; as a result, the inverter is able to use a much smaller transformer. The result is a substantial reduction in size and weight. Energy consumption also decreases as the more efficient transformer loses less energy for heating. It is possible to operate these welders on a typical household current of 115VAC due to the lower input voltage requirements.
Due to the higher frequency of the output current, an inverter welder produces a choking arc during welding. The computer software constantly monitors and adjusts the current and voltage during the welding process, resulting in a consistent arc. As a result, welding supplies such as electrodes, welding wire, and shielding gas typically last longer than when using a traditional welding power supply. Adjustments can be made to the current and voltage to accommodate for differences in material composition and thickness, giving the welder tighter control over the welding process. An inverter welder can be used to power all welding processes including Stick, Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG).
The small size and weight of these welders make them popular choices for applications where a traditional welding power supply would be too bulky or consume too much energy. They are commonly used in machinery maintenance facilities and automobile repair shops. Many welding and fabrication shops are replacing their traditional welding power supplies due to the potential cost and space savings offered by inverter welders. Farmers are also increasingly turning to portable, lightweight units to carry out on-the-spot repairs.
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