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Inverter welding is a very useful manufacturing process. Compared with traditional copper-wound transformers, inverter welders have many different advantages. The most significant benefits are size and weight. The inverter is smaller and is a fraction of the weight of the transformer-based machine, so it is lighter and more portable. Compared with old transformer-type machines, inverters use less input power to obtain the same output power, so they consume much less electrical energy and therefore run more environmentally friendly.
In short, an inverter welder is an electronic system for voltage regulation. For inverter welding machines, it converts AC power to a lower usable output voltage-for example, from 240V AC power to 20V DC output.
Unlike traditional transformer-based equipment, which mainly relies on a single large transformer to regulate voltage, an inverter welder uses a series of electronic components to convert power. Since the power output of the inverter is electronically controlled, an unlimited amount of power can be adjusted.
In most cases, use the rotary control knob to adjust the power output of these modules, allowing fingertip adjustments between 0 and 100%. This allows the user to accurately and finely control the welding output to suit any given application. It is often found that traditional welding machines have many stepping settings. These settings have limitations. Two of them may not be powerful enough, but three are too many. Using an inverter welder, the welding power output can be accurately set at the desired position.
This is the most significant and impressive advantage of inverter welding, compared with traditional welding machines. For example, an inverter welder that weighs less than 5 kg, is smaller than a suitcase, and can be hung comfortably on the shoulder, may have an output capacity equivalent to a 50 kg transformer-based machine.
High-quality inverter welders will have an efficiency rating of about 80-90%, while the efficiency of conventional welding machines will be greatly reduced, about 50%. This is due to the fact that a large transformer in a conventional machine has a large resistance and therefore loses a lot of power (or energy) through heat dissipation.
The high efficiency means that an inverter welder is much more feasible to use generator power with inverter welding machines, which can be operated on smaller portable generator sets-which is usually not possible on traditional transformer machines. It should be noted that there are risks associated with using generator power-for more information, please read our other welding related articles.
Similarly, due to the difference in transformer size, the use of inverter-based motors can usually achieve a higher duty cycle. Although the smaller components in the inverter welder heat up quickly, they can be cooled easily and quickly. However, in traditional "transformer" welding machines, the components are much larger, so they tend to store heat and require longer cooling times.
Many traditional "transformer" MMA (bar type) welders have only AC output, which means they are limited in the types of electrodes that can be welded. However, for inverter welding operations, the current is more easily rectified into direct current, which means that they can weld a variety of different welding electrodes. This also means that some MMA (bar type) inverters are also suitable for DC TIG welding, which is not possible with conventional AC machines.
The performance of high-quality inverter welders is significantly better than traditional welding machines. This is especially noticeable in MMA (bar) welding, because the operator finds the welding much easier without the need to "play" the arc. This is mainly due to the fact that the inverter machine has a higher open circuit voltage and has the capabilities of functions such as hot start, anti-sticking and arc forced.
A typical example is the inverter welding of thin materials: it is very difficult if not impossible to use a traditional rod welding machine, but if the inverter machine has unlimited amperage adjustment and a very stable arc, it can turn down the output to a very low level, so that's it. It is relatively easy and controllable to weld 1.6mm metal plates or pipe sections.
The electronic equipment of the inverter welder is easier to realize the ability to incorporate other functions, such as TIG mode, and make existing inverter welding functions more controllable.
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