Novel and simplified implementation of digital high-power pulsed MIG welding power supply with LLC resonant converter

Purpose This paper aims to overcome the limitations of low efficiency, low power density and strong electromagnetic interference (EMI) of the existing pulsed melt inert gas (MIG) welding power supply. So a novel and simplified implementation of digital high-power pulsed MIG welding power supply with LLC resonant converter is proposed in this work. Design/methodology/approach A simple parallel full-bridge LLC resonant converter structure is used to design the digital power supply with high welding current, low arc voltage, high open-circuit voltage and a wide range of arc loads, by effectively exploiting the variable load and high-power applications of LLC resonant converter. Findings The efficiency of each converter can reach up to 92.3%, under the rated operating condition. Notably, with proposed scheme, a short-circuit current mutation of 300 A can stabilize at 60 A within 8 ms. Furthermore, the pulsed MIG welding test shows that a stable welding process with 280 A peak current can be realized and a well-formed weld bead can be obtained, thereby verifying the feasibility of LLC resonant converter for pulsed MIG welding power supply. Originality/value The high efficiency, high power density and weak EMI of LLC resonant converter are conducive to the further optimization of pulsed MIG welding power supply. Consequently, a high performance welding power supply is implemented by taking adequate advantages of LLC resonant converter, which can provide equipment support for exploring better pulsed MIG welding processes.