Inverter welding technology is used in many fields from industry and construction to household. Since the organization of the working process requires the connection of an electricity source, in remote conditions (at the cottage or construction site) it will not be possible to do without an autonomous power supply station. For such cases, it is recommended to have a generator in the arsenal for welding with an inverter with suitable characteristics.
Function of the generator as part of the welding equipment
Inverter welding technology provides for connection to electric networks with a voltage of 220 or 380 V, depending on the nominally required power of the device. A typical inverter starts the power station in manual or automatic mode, after which the process of power supply starts, arc ignition, etc. The generator set basically focuses on replacing the main power line, but the characteristics and operating modes may vary depending on the model. Also, a set of additional functions is determined by the specifics of autonomous energy supply. In the field of operation, the importance of protective options (from overheating or overload), automatic regulators and instrumentation is increasing.
Is there an alternative to an inverter welding generator? Only autonomous power supply stations based on natural renewable energy sources are fundamentally different - like solar panels and windmills. But in this case, there are serious restrictions on the use of equipment. Firstly, the generator’s mobility property is completely excluded, and secondly, it is not always possible to maintain the required power, since the intensity of energy storage depends on climatic conditions.
What types of welding generator are there?
There are a lot of classifications of generators, but at the basic level, two main groups can be distinguished:
- Synchronous. They are notable for the low quality of the supplied current, but can be used as a temporary backup source. Moreover, the advantages of such devices include qualities important for remote welding, such as resistance to short-term and peak loads. On the other hand, the cooling system of a synchronous generator for inverter welding requires air circulation, which brings particles of dust, dirt and moisture. Therefore, on the street to use such a installation can only be in favorable weather conditions.
- Asynchronous. Not so effectively cope with peak loads, but they maintain voltage with high accuracy. For overload sensitive welding equipment, this is a more attractive solution. The pluses of asynchronous generators include the lack of a cooling system - in principle, it is not required, therefore the design is completely sealed and protected from dirt and moisture.
Optimum fuel
Autonomous power plants can operate on gasoline, diesel and gas mixtures. It should be emphasized right away that gas generators with significant advantages (low fuel cost and high resource) are not suitable for welding inverters due to high safety requirements. Accordingly, the choice will be between gasoline and diesel technology. A standard 5 kW gas generator, the average price of which is 30-40 thousand rubles, will not cause problems in working conditions at low temperatures (up to -15 ° C) and will provide a resource of about 2000 thousand engine hours. Such equipment cannot be called compact and environmentally friendly, but compared to diesel models, these properties look more attractive.
A diesel engine is economically justified because the generator will consume this fuel more slowly. Depending on the design, you can count on low noise and resistance to external influences. Typically, such models are used in large industries and in cases where high productivity of the welding machine is required. An average 10 kW diesel generator can cost 150-200 thousand rubles. The working life of such a station will be 20000-30000 hours, if a liquid cooling system is provided.
Selection of current characteristics
This parameter ultimately determines the speed and quality of work on the connected welding machine. The average range is from 5 to 200 A. In determining the approximate strength of the welding current, you should focus on the thickness of the electrode - for example, for a bar with a diameter of 4 mm, a maximum value of 180-200 A is required. The lower bar is 2 mm and 5-20 A, respectively. Moreover, there are highly specialized welding methods using alloyed electrodes with a thickness of more than 8 mm. In this case, you need a generator with support for currents above 500 A.
Also takes into account the type of current - direct or alternating. Direct current, which is used in arc welding, is considered more effective. In this case, it is possible to achieve stability of ignition of the electric arc and sustainable combustion in the future. But a generator for welding with an inverter with alternating current may be useful - for example, when working with carbon steels.
Voltage and power - what to consider?
First of all, the voltage is determined. As already noted, it can be 220 V or 380 V. Low-power generators for a welding inverter are usually powered by single-phase networks, and high-performance ones from three-phase ones.
How to calculate power? This is the nominal value of the inverter apparatus, which is indicated in its technical passport. Another thing is that the summation of several consumers participating in the welding process may be required. Next, multiply the detected value by the inrush current coefficient (depending on the inverter model) and add 10% for overload insurance. As practice shows, the same 10 kW diesel generator may well cover the needs of a small production or work area where the main pipeline is welded.
The economic nuances of choosing a generator
The welding equipment is very energy-consuming and the following factors will have considerable value in terms of economy:
- The ability to adjust power. Fine-tuning the engine speed is a universal means of minimizing energy resources.
- Type of fuel. It has already been said that the choice by this criterion is reduced to gasoline and diesel units. According to experts, for a 5 kW gas generator, the price of 1000 working hours averages 120-130 thousand rubles. At diesel stations, the costs for this parameter are much lower - 70-80 thousand rubles.
- The presence of protective systems. A kind of voltage limiter and other parameters of energy supply, due to which the risks of breakdowns and, therefore, the likelihood of costly repairs are reduced.
Stationary or mobile generator?
Operating conditions may impose different requirements on the possibilities of transporting an autonomous energy source. In factories in industry or in large-scale construction, the choice usually falls on stationary equipment. Mainly because of the high power with a current strength of up to 500 A. In turn, mobile power plants are indispensable in the arsenal of field teams performing simple welding operations with electrodes with a diameter of up to 4 mm.
Additional selection criteria
Typically, many ignore the ergonomic nuances of choice, paying more attention to performance. But the convenience of physical treatment in the long run is an important factor in obtaining a qualitative result. It is advisable to give preference to generators for a welding machine with wide adjusting functionality, the presence of handles on the body and the transportation base. Users also praise modern LCD displays with electronic control - through such a panel it is convenient to monitor the current operating indicators of the device and make the necessary adjustments.
Conclusion
The market for welding equipment and power plants today is crowded with various options for autonomous energy sources. If we talk about foreign manufacturers, it is recommended to immediately turn to the products of FUBAG, Honda, SDMO, TELWIN, Endress, etc. Those who expect to purchase an inexpensive mobile power plant for the home should take a closer look at the domestic lines. The best price and quality offers can be found in the assortments of the Vepr, Svarog and PRORAB manufacturers. And in each case, the universally correct approach to the choice will be a comprehensive account of the full range of requirements for the generator.