Reactive-power compensation for voltage control at resistance welders

Resistance welders are a source of voltage fluctuations and flicker in industrial power distribution systems. The high-reactance welding transformer that limits the welding current creates a low-power-factor (pf) load. With hundreds of welders, factories may use synchronized welding cycles that lead to annoying flicker. Other facilities use random timing to prevent flicker, but suffer deep voltage sags due to simultaneous welding operations. Severe voltage variations reduce the power delivered to the welders, causing reduced heating and poor-quality welding joints. The paper examines the design and application of a mini-static var compensator (SVC) to improve the voltage quality on the welding circuits of industrial power distribution systems. The compact range of reactive-power demands for robotic welders suggest the use of thyristor-switched capacitors (TSCs). The compensation provides the necessary voltage control for consistent welds with the added benefit of reduced load currents throughout the industrial distribution system. The compensator control is coupled with the welder controls to mitigate the random reactive-power mismatches that are often seen with other SVC welding and arc-furnace applications.