WELDING TRAFO
Welding Trafo
Welding trafo is another name for welding inverter or electric welding machine. Travolas is the name given to people in Indonesia for the electric welding machine itself. The habit of Indonesian people is often to mention an object or tool from its shape. And the shape of this electric welding machine is in the form of a box like an electric transformer. And just like a transformer that has two right and left clamping sockets that have an electric current of min (-) and plus (+), this welding transformer or electric welding machine also has 2 sockets min(-) and plus(+).
Welding trafo is a machine that is used to carry out welding activities both outdoors and indoors, as long as it has a power source to turn on the welding transformer. While the definition of welding itself is a process of joining two or more objects to become one. It can be interpreted that a welding transformer is a project tool used to connect iron/metal materials using welding wire.
In the welding technique using this welding transformer, it can be divided into two types of power sources, namely:
- Welding trafo whose power source is by using a generator / generator.
- Welding trafo whose power source is from a transformer / electrical installation
In general, welding can be divided into two, namely welding metal and welding plastic. But because what we are discussing now is transformer welding, so here it is devoted only to welding on metal materials. And in this welding system, there are several things that you should pay attention to, including:
- The type of object to be welded.
- The size of the electrode used.
- Type of welding transformer used
If viewed from the flow that comes out, welding planes can be classified into:
1. Alternating current (AC) welding machine
This machine requires alternating electric current or AC current generated by a power plant, PLN electricity or AC generator, which can be used as a power source in the welding process. The amount of electrical voltage generated by the power plant source is not in accordance with the voltage used for welding. Bisa terjadi tegangannya terlalu tinggi atau terlalu rendah, sehingga besarnya tegangan perlu disesuaikan terlebih dahulu dengan cara menaikkan atau menurunkan tegangan.
The device used to increase or decrease this voltage is called a transformer or transformer. Most of the transformers used in welding equipment are step-down transformers, which are transformers that lower the voltage. This is because most sources of electricity, both PLN electricity and electricity from other sources, have a fairly high voltage, even though the required voltage issued by the welding machine for welding is only 55 volts to 85 volts.
The transformer used in welding equipment has a large enough power. To melt some of the base metal and electrodes it takes a lot of energy, because the voltage at the terminals of the secondary coil is only small, so to produce a large amount of power, a large current is needed. The current used for welding equipment is about 10 amperes to 500 amperes. The amount of electric current can be adjusted according to welding needs. For large power purposes, a larger current is required, and vice versa.
2. Direct current (DC) welding plane
The electric current used to produce an electric arc is direct current. This direct current comes from the engine in the form of a direct electric motor dynamo. The dynamo can be driven by an electric motor, gasoline motor, diesel motor, or other propulsion device. Current machines that use an electric motor as a driving force initially require equipment that functions as a current rectifier. Current rectifier or rectifier serves to convert alternating current (AC) into direct current (DC). Alternating current converted into direct current in the welding process has several advantages, including:
- The electric arc produced is more stable,
- Any type of electrode can be used in DC welding machines,
- Lower noise level,
- Welding machines are more flexible, because they can be converted to AC / DC current.
There are 2 kinds of DC welding machines, namely stationary welding machines or portable welding machines. Stationary welding machines are usually used in places or workshops that have a permanent electricity network, for example PLN electricity. The portable welding machine which has a relatively small form is usually used for welding processes in places that are not covered by the electricity network. The thing that needs to be considered in the operation of the welding machine is the use in accordance with the procedures issued by the machine manufacturer, maintenance in accordance with the recommendations. Often disturbances arise in the welding machine, including the machine does not produce an electric current or the electric arc is weak.
3. AC-DC welding plane
This welding machine is able to serve welding with direct current (DC) and welding with alternating current. The double welding machine has a single phase transformer and a grader in one machine unit. The alternating current output is taken from the transformer secondary winding terminal through the current regulator. The direct current is taken from the output of the current leveler. Setting the output of alternating current or direct current can be done easily, by simply turning the current regulator of the welding machine. AC-DC welding machines are more flexible because they have all the capabilities of each DC welding machine or AC welding machine. This type of welding machine is often used for workshops that have various types of work, so there is no need to change welding for different welding.
Welding Cable
In addition, the components of the electric welding machine are welding cables. This one component usually consists of several types. Welding cables are usually made of selected copper and wrapped with insulating rubber. The welding machine usually consists of several types. In welding there is usually a primary cable and also a secondary cable (welding cable). The primary cable itself is a cable that is used to connect the power source and also the welding machine. While the secondary cable is a cable that is used for welding. The secondary cable itself is divided into 2, namely the electrode clamping cable (pliers) and the workpiece clamping cable (holder).
Welding Mass Clamp
The material used to make the mass clamp and electrode holder is a material that easily conducts electricity. The material commonly used to make mass clamps and electrode holders is copper. The webbed end of the electrode is clamped with an electrode holder. It consists of a clamp mouth with a holder wrapped by an insulating material (usually of embonite).
Electrode Clamp (Holder)
In the electrode holder or holder, the part for clamping the electrode has been made in such a way as to be able to clamp the electrode firmly so that when used to weld the electrode it does not fall. Meanwhile, to clamp the mass is also made in such a way that it can clamp the object to be welded firmly.
Electrode / Welding Wire
Welding wire or what is often referred to as an electrode is a material used to perform electrical welding which functions as a burner that will cause an arc of flame. As one of the important parts in the welding process, the user must understand the use of each type of electrode. The webbed electrode consists of two parts with different functions, namely:
- Electrode Core Parts, Which Function:
a. As a conductor of electric current from the electrode pliers to the arc formed, after contact with the workpiece.
b. As an additive
As for materials, the electrode core is made of ferrous and non-ferrous metals, such as carbon steel, alloy steel, aluminum, brass and others. - Electrode Coating Part, Which Function:
a. To provide a protective gas to the metal being welded, protecting against air contamination when the metal is in a molten state.
b. Forms a slag layer, which coats the weld resulting from air oxidation during the cooling process.
c. Prevent the cooling process from being too fast.
d. Easy ignition.
e. Controls arc stability.
Coatings on electrodes that have been opened from their packaging must be stored in a heating cabinet or oven at a temperature of 15 degrees higher than the outside air temperature, because the coating is very sensitive to moisture. If left damp, it will cause the following:
- The coating peels off easily, making it difficult to ignite
- Excessive splash
- Unstable arc
- Excessive smoke
Support Tools and Safety in Welding
- Welding helmet/mask.
- Welding gloves.
- Apron / welding work clothes.
- Pliers (clamp).
- Welding hammer / chip.
- Safety welding shoes.
- Wire brush.
- Mask.
- Hand grinder.
- Welding safety goggles.
