Modeling and Control of a Full-Bridge DC-DC Converter for Arc Welding Applications

Christian  G. Barbosa; Vitor de S. Guedes; Rafael C. Beltrame; Lucas V. Bellinaso; Fábio E. Bisogno; Ezequiel  A. Mallmann; Luciano A. Fricke

doi:10.18618/REP.e202602

Authors

Christian G. Barbosa Federal University of Santa Maria https://orcid.org/0009-0005-1733-9072
Vitor de S. Guedes Federal University of Santa Maria https://orcid.org/0009-0006-6334-8591
Rafael C. Beltrame Federal University of Santa Maria https://orcid.org/0000-0002-8132-7587
Lucas V. Bellinaso Federal University of Santa Maria
Fábio E. Bisogno University of Applied Sciences Koblenz https://orcid.org/0000-0002-2006-3899
Ezequiel A. Mallmann Fricke-Balmer Soldas Ltda https://orcid.org/0009-0002-8554-1844
Luciano A. Fricke Fricke-Balmer Soldas Ltda https://orcid.org/0009-0003-8208-7233

DOI:

https://doi.org/10.18618/REP.e202602

Keywords:

Arc welding, Converter modeling, Dual-loop control, GMAW modeling

Abstract

This study presents the modeling and control of a full-bridge DC-DC converter applied to Gas Metal Arc Welding (GMAW) in short-circuit transfer mode. GMAW is widely used in industrial manufacturing due to its versatility. However, achieving stable operation in short-circuit transfer requires precise regulation of the welding current and arc voltage. To address this challenge, a simplified yet representative model of the converter and load dynamics is developed. Based on this model, a dual-loop digital control strategy is implemented to ensure fast transient response, reference tracking, and improved stability of the welding process. The effectiveness of the proposed approach is experimentally validated on an industrial-grade prototype, demonstrating agreement between theoretical predictions and measured waveforms.

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Author Biographies

Christian G. Barbosa, Federal University of Santa Maria

Christian G. Barbosa was born in Ijuí, Brazil, in 1996, he received the B.S. degree in Electrical Engineering from the Northwest Regional University of the State of Rio Grande do Sul (UNIJUÍ), Brazil, in 2019, and the M.S. degree in Electrical Engineering from the Federal University of Santa Maria (UFSM), Santa Maria, Brazil, in 2023. He is currently pursuing the Ph.D. degree in Electrical Engineering at UFSM. Since 2017, he has been conducting research and development activities related to innovative welding equipment as a member of the R&D team at Balmer – Fricke Soldas. His research interests include control applied to power electronics, industrial automation, embedded systems and control systems, welding processes, and technological innovations in welding.

Vitor de S. Guedes, Federal University of Santa Maria

Vitor de S. Guedes was born in Santa Maria, Brazil, in 2000. He is currently pursuing the B.S. degree in Control and Automation Engineering at the Federal University of Santa Maria (UFSM), Santa Maria, Brazil. Since 2023, he has been a member of the Power Electronics and Control Research Group (GEPOC) at UFSM. He is involved in an extracurricular research and development project focused on the modeling, analysis, and implementation of digital control systems for power electronic converters. His areas of interest include control applied to power electronics, industrial automation, embedded systems and instrumentation.

Rafael C. Beltrame, Federal University of Santa Maria

Rafael C. Beltrame was born in Santa Maria, Brazil, in 1984. He received the B.S., M.S., and Ph.D. degrees in electrical engineering from the Federal University of Santa Maria, Santa Maria, Brazil, in 2008, 2009, and 2012, respectively. He has been with the Power Electronics and Control Research Group (GEPOC) at UFSM since 2005. Since 2013, he has been affiliated with UFSM, where he currently holds a position as a Professor. From 2015 to 2021, he served as the Manager of the High-Voltage Laboratory at the Smart Grids Institute of UFSM. His research interests include highperformance power converters, control applied to power electronics, fast chargers for electric vehicles, and testing of electric power transformers.

Lucas V. Bellinaso, Federal University of Santa Maria

Lucas V. Bellinaso received his B.S., M.Sc. and Ph.D. degrees in electrical engineering from the Federal University of Santa Maria (UFSM), in 2012, 2014 and 2017, respectively. Since 2015, he has been with the Power Electronics and Control Group, where he is currently Professor. His research interests include PV systems, power electronics and control applied to renewable energy systems, and safety of PV systems. Additionally, he is currently National Secretary of ABNT/CB-003/CE 003 082, the Brazilian mirror committee of IEC TC 82.

Fábio E. Bisogno, University of Applied Sciences Koblenz

Fábio E. Bisogno received the B.S. and M.S. degrees in Electrical Engineering from the Federal University of Santa Maria (UFSM), Santa Maria, Brazil, in 1999 and 2001, respectively, and the Dr.-Ing. degree in Electrical Engineering from the Technische Universität Chemnitz, Chemnitz, Germany, in 2006. During his doctoral studies, he worked as a Research Engineer at the Fraunhofer Institutes for Autonomous Intelligent Systems (AIS), Reliability and Microintegration (IZM), and later at the Institute for Artificial Intelligence (IAIS), Germany, participating in the conception, design, and development of industrial products for leading companies. From 2009 to 2023, he served as an Associate Professor at UFSM, contributing to the CAPES level-7 graduate program and leading R&D projects in collaboration with electric utilities and industry, with a strong focus on innovation. He is currently a Professor of Electronics in Germany, at the University of Applied Sciences Koblenz (Hochschule Koblenz). His research interests include resonant converters, electronic ballasts, self-oscillating systems lighting systems, and power generation systems using internal combustion engines.

Ezequiel A. Mallmann, Fricke-Balmer Soldas Ltda

Ezequiel A. Mallmann was born in Mondaí, Santa Catarina, Brazil, in 1987, he received the B.S. degree in Electrical Engineering from the Northwest Regional University of the State of Rio Grande do Sul (UNIJUÍ), Brazil, in 2014. Since 2008, he has in charge of research and development department, developing activities related to innovative welding equipment as a manager of the R&D team at Balmer – Fricke Soldas. His research interests include control applied to power electronics, industrial automation, embedded systems and control systems, welding processes, and technological innovations in welding.

Luciano A. Fricke, Fricke-Balmer Soldas Ltda

Luciano A. Fricke received the B.S. degrees in electrical engineering from the Federal University of Santa Maria, Santa Maria, Brazil, in 2004. He is currently the Industrial Director and Technical Manager of Fricke Soldas LTDA. He is also the coordinator of the company’s research, development and innovation center and coordinator of technological innovation projects in cooperation with companies from Germany, Italy and China.

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