Welding power supply

With a CC machine the welder can count on a fixed number of amps reaching the material, regardless of how short or long the electric arc gets.

The trade off for the reduced expense is that pure transformer designs are often bulky and massive because they operate at the utility mains frequency of 50 or 60 Hz.

The transformer may also have significant leakage inductance for short circuit protection in the event of a welding rod becoming stuck to the workpiece.

Modern designs are usually driven by an internal combustion engine but older machines may use an electric motor to drive an alternator or generator.

Since the advent of high-power semiconductors such as the insulated gate bipolar transistor (IGBT), it is now possible to build a switched-mode power supply capable of coping with the high loads of arc welding.

Although the high switching frequency requires sophisticated components and circuits, it drastically reduces the bulk of the step down transformer, as the mass of magnetic components (transformers and inductors) that is required for achieving a given power level goes down rapidly as the operating (switching) frequency is increased.

Typically, the controller software will implement features such as pulsing the welding current, providing variable ratios and current densities through a welding cycle, enabling swept or stepped variable frequencies, and providing timing as needed for implementing automatic spot-welding; all of these features would be prohibitively expensive to design into a transformer-based machine, but require only program memory space in a software-controlled inverter machine.

Similarly, it is possible to add new features to a software-controlled inverter machine if needed, through a software update, rather than through having to buy a more modern welder.