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I am looking to develop a power electronics board to do DC welding with a current range of 0 to 120A or greater. The input to this welder circuit will be from a DC battery source. The battery voltage may be defined by the circuit designer but should probably be less than 100VDC. The welding circuit module should include thermal management design for a 20% welding duty cycle or better at full current.
A compact switching design is preferred so that the welder unit will be portable and light weight. The high current semiconductors may be cooled by thermal connection to a heat sink or the steel case of the final product. A cooling fan may be used as required.
To assure good welding performance the designer will have to define optimum parameters for arc initiation and arc stability throughout the weld current range. Performance specifications will need to be similar and competitive to DC welders that operate from AC line power.
The end product will be a portable, self contained...
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