Efficient SMAW Arc Controller for Wide Range Applications and also for Emerging Economies

Due to simplicity of arrangement, initial-cost implication and ease of process learning the shielded metal arc welding process (SMAW) is more popular in developing and underdeveloped countries. Apparently, this manual process needs simple constant current power source. Large number of welding consumables have made the arc characteristics of the process quite diverse; the current range for this non-linear process is wide. The input energy source to feed the arc controller could have diverse output characteristics, it could be from infinite bus i.e. the national grid or moderate size diesel generators in isolated locations (e.g. for pipeline welding) or from mini and micro grids in emerging economies. To make the power controller ideally compatible to the process behavior, that includes the wide range non-linear arc characteristics, as well as to the varied input source, it should be able to create requisite joint characteristics drawing minimum input current from the input source. This article details the features of arc controller meeting the wide range applications in the presence of source constraints and details one such equipment with experimental details. It also details the design of mini grid compatible arc controller.