Why MFDC Welding is superior to AC Output Welding

Posted on Aug 27, 2020

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Why MFDC Welding is superior to AC Output Welding

The abbreviation MFDC stands for three-phase mid-frequency direct current. This is a control and power supply system that uses AC power input and converts it to inverted high-frequency power output at three-phase AC 60 Hz input. It has become the norm when purchasing new resistance-welding machines as this technology allows for savings in cycle time, consumables and power usage.

MFDC is  a welding technology that uses power inverters to convert AC into a DC electrical current for resistance welding operations and finally get an inverted DC output of 400-4000 Hz. Compared with conventional DC welding, using an MFDC controller can bring many benefits. In this article, we will introduce all the advantages of MFDC welding and discuss its 3D welding capabilities.

 

Advantage No. 1: Energy Efficiency

In addition to proper maintenance, one of the biggest costs of using automatic welding machines is power requirements. Machines need the power to run, and electric welding equipment is no exception. However, compared with AC welding machines, MFDC welding machines consume less power. why? Because, because the MF inverter absorbs balanced line currents in all stages of welding, compared to AC welding machines, MF-based welding has lower power requirements. Compared with AC-based welding technology, the MFDC welding machine can save up to 35% of the power.

 

Advantage No. 2: Reliability

In addition to using less overall power, because MFDC welding machines use power inverters to supply power to the welding head, it is unlikely that machines using MFDC welding will be adversely affected by short-term power supply interference. When using an AC welding machine, any current interference flowing to the machine will immediately affect the welding head. When using an intermediate frequency inverter, there will be some electricity stored in the inverter, so a smaller power will not immediately stop the welding machine. In addition to using less power overall, since MFDC welding machines use power inverters to supply power to the welding head, machines using MFDC welding are unlikely to be adversely affected by short-term power interference. When using an AC welding machine, any current interference flowing to the welding machine will immediately affect the welding head. When using an intermediate frequency inverter, some electricity is stored in the inverter, so a smaller power will not immediately stop the welding machine.

 

Advantage No. 3: Weld Speed

Since power fluctuations will not adversely affect MF welders like standard AC welders, the welding time of MF welders is actually shorter. Most notably, the 1,000Hz performance of the MF inverter indicates the present waveform is shorter than that of the AC device. The MF inverter has a shorter wavelength and can monitor the welding time within milliseconds, allowing 20 or AC welding The system's timing accuracy is 30 times. Traditional welding will slow down the production cycle. The reason why we believe that automatic AC welding surpasses manual welding technology is that it is many times faster than the traditional welding process. Manual welding takes a few seconds or more to complete, so AC welding can be completed in 60/1,000 seconds, which limits the stress deformation in welding. MFDC welding is even faster than AC welding. For the MFDC welding method, welding can be done in 2/1,000 seconds, which is approximately 30 times faster than the AC welding machine. This guarantees better welding efficiency while reducing spatter, blister, and other weld distortions.

 

Advantage No. 4: Weld Quality

By completing the welding faster, MFDC welding can prevent most of the thermal deformation and spatter normally associated with AC welding. The fact that the peak voltage of the MFDC welding is almost the same as that of the RMS voltage further helps to reduce the sparks and spatter produced by AC welding. Since welding can be done in 2/1,000 seconds instead of 60/1,000 seconds and the pressure applied during welding is lower compared to MFDC welding, there is less harm to the metal parts welded by MFDC by AC Welding contact. This allows the final product to have higher structural integrity, thereby increasing its overall durability and service life. In addition to the structural advantages of MFDC welding, the nugget left by MFDC welding is usually smaller and smoother than that left by AC welding. This can reduce the safety of the final product after manual welding because it can reduce the sharp edges remaining after welding. In products where burrs and other sharp edges must be removed, this will greatly reduce the time required to prepare the parts for shipment, because there are fewer sharps to clean.

 

MFDC Weld Performance Factors

Adaptive resistance MFDC welding control uses cutting edge control platforms to change the specific functional characteristics of the welding device in real time so that every weld is carried out within the strictest tolerances of efficiency. It provides a structure that greatly reduces or theoretically eliminates ultrasonic weld inspection technology. Typical manual ultrasonic inspection methods include removing the sample component from the line and subjecting it to a manual, stand-alone inspection – as a measure of the consistency of the specific welding process during the production run. Although it is non-destructive, it is time consuming and has the ability to create frequent contradictions, depending on the judgment of the tester as to what constitutes good welding. Adaptive resistance welding technology combines the inspection of each weld and the real-time monitoring of how each weld is conducted to significantly increase the reliability of the welding process and at the same time achieve the highest level of welding throughput.

 

More information about welding machine

1. Projection Welding is the Boss of Embossments

2. Read this to understand Resistance Spot Welding!

 

MFDC Welding Machines on IMTS-Exhibition.com

We hope you found this article on MFDC welding and its advantages useful! You can find many MFDC Welder manufacturers on our site that are suitable for a wide range of industries. Just head to our product section or check out our search function to find all related companies in our product database.  If you want to learn more about CNC machinery related questions and their applications make sure to check out our other blog entries. 

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