Electrical & Electronics Engineering

Design and Construction of an Arc Welding Machine

Design and Construction of an Arc Welding Machine


The machine is designed to serve with an output of 250A. it has two pats which are the primary and secondary parts. The primary part, through which voltage is supplied to the machine has 180 turns which is made of 2mm2 S.W.G 14 copper coil. The secondary part has 45 turns made of 4mm2 S.W.G 8 copper coil.

Both turns are wound on separate limb of the laminated core. The voltage from primary turns flows to the secondary turn by induction.

The machine contain a power switch through which the machine can be switched on or off when connected to the power source. The indication light simply shows when the machine is on or off which is equally controlled by the power switch.

The fan connected to the machine helps in the looking of the temperature of the machine, it gets started once the machine is on.

The welding current is adjusted by varying the spacing between the primary and secondary windings when the cranks is rotated, clockwise the insulating block between the two winding moves down, the magnetic flux leakage and the inductive impedance are increased, thereby reducing the welding current in the secondary windings. Also as the insulating block is moved upward, away between the two turns, the magnetic flux leakage and the inductive impedance are brought down, causing the welding current to rise.

Title Page/Approval Page
Table Of Content
Chapter One
1.0 Introduction
1.1 Aims/Objective
1.2 Scope Or Limitation
1.3 Definition Of Terms

Chapter Two
2.0 Literature Review
2.1 Transformer Design
2.2 Coil Design
2.3 Core Design
2.4 Equivalent Circuit Of The Machine
2.5 Machine Design
2.6 Operation Of Machine
2.7 Leakage Flux Reduction
2.8 Specification From Design

Chapter Three
3.0 Construction
3.1 Lamination
3.2 Transformer Former
3.3 Copper Coil
3.4 Insulating Materials
3.5 Methodology
3.6 Casing
3.7 Coupling
3.8 Electrical Holder

Chapter Four
4.0 Testing And Finding
4.1 Open-Circuit Test
4.2 Short-Circuit Test
4.3 Test Analysis
4.4 Conditions For Operation
4.5 Cost Analysis

Chapter Five
5.0 Conclusion
5.1 Recommendation

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