Design of special power source for dual-arc pulsed MIG welding and test analysis

Dual-arc pulsed MIG welding is a low-energy input welding method. The original dual pulse power supply system employed in dual-arc pulsed MIG welding is complex, difficult to control and susceptible to interference. For this problem, a design scheme of integrative special power supply for dual-arc pulse MIG welding was proposed. The synergetic control of two pulse current flowing through main and bypass arc was achieved by the same control system. A main circuit based on the limited bipolar full bridge inverter and a control circuit based on DSP2812 were designed. Then, the model for integrated special power supply system was built and the feasibility of the design scheme was verified by simulation. On this basis, low-energy input welding tests were also carried out to join aluminum alloy to galvanized steel. The results showed that the designed integrative special power supply can meet the requirement of dual-arc pulsed MIG welding and well welding quality can be achieved under low-energy input conditions.