Design and Development of Improved Micro Butt Welding Power Plant

Butt welding is extensively used in different industries such as chains, rods, pipes, flanges, frameworks, etc. In Pakistan, machines for the stated purpose are usually imported from other countries, resulting in increased setup costs. Local manufacturing of this machine decreases setup costs and enables aftersales services by the manufacturer to its users. This paper presents the design and implementation of the improved resistance butt welding machine in terms of price, control mechanism to improve productivity, and complexity in implementation. The designed power plant incorporates a single-phase AC transformer, suitable electrodes for supplying current to the weld and arrangement for controlling the mechanical pressure, and means for controlling the duration of weld current flow. A step-down transformer is designed to produce the required high current and low voltage at its output. Finite Element Analysis (FEA) of the designed transformer is carried out in ANSYS® Maxwell to validate the design, and then hardware implementation of the transformer is carried out. The mechanical setup of the machine following the fundamental principles of resistance welding is designed and implemented. A timing mechanism is employed to control the welding operation. The machine is made protected from high current faults such as earth faults or an electric shock to the operator, using a fuse as a protective device. Two iron rods are welded after the implementation of the welding plant.