Optimizing Design Of Magnetic Components In Plasma Cutting Power Supply System

With the all-around development of the national economy,the metal manufacturing and processing industry has made great progress in its scale and technology.The nation is promoting and implementing the policy of“replacing casting with welding”,which made the total volume of the cutting materials of the metal plates increase year by year,and also poses increasingly high requirement for the material-cutting efficiency and quality.The number of the Plasma cutting machine increased from 12000 units in 2014 to 16000 units in 2015.This proves that there is a huge market for plasma cutting in China and an even greater market globally.Cutting is the first working procedure of welding,which is used for subsequent process and welding.The flexibility scope of cutting surface quality rate,cutting efficiency,the successful molding rate and utilization rate affect the welding quality of the products and the production cost.So the development of modern industry needs the cutting devices.The BUCK DC-DC converter of Plasma cutting machine requires high power and high thermo magnetic components,including a phase-shifting transformer and two sets of DC reactor.Generally,if the output current is 260 A,the loss of all the magnetic components will reach more than several k W,which seriously limits the increase of conversion efficiency.Therefore,the efficient magnetic materials and the design schemes are adopted;the low loss phase-shifting transformer and DC reactor are studied and made.The main research work and innovation points of this paper are as follows:Firstly,the optimized magnetic material is determined by analyzing the function and principle of magnetic components,the magnetic components structure and magnetic structure are confirmed by analyzing the characteristics and matters needing attention of magnetic materials,which will reduce winding loss and core loss.The heat is calculated by determining specifications of winding wires.Based upon all of these,the optimized design schemes are prepared.Secondly,the electrical design principle of BUCK DC-DC converter is analyzed for plasma cutting power supply,the design requirements of phase-shifting transformer and DC reactor are mastered for plasma cutting power supply,the complex relationships include voltage transformer ratios,inductance,switching frequency,rated current,ripple current,the cooling ways are restricted.Thirdly,the magnetic circuit parameters are auxiliary calculated by using the finite element electromagnetic simulation software MAXWELL.Various design schemes are determined under different electrical parameters,such as switching frequency,inductance and pulses of phase-shifting transformer,guide the actual magnetic components design.The target is to reduce the size and loss of magnetic elements by 15%.Finally,optimizing design of phase shifting transformer and DC reactor for the plasma cutting power supply provide preferred magnetic material silicon sheet,provide variety of choice to reduce the size and the heat of the two magnetic components,thereby improve the conversion efficiency and ensure high cost-effective indicators.