High frequency transformer with synchronous rectifier for resistance spot welding

Resistance spot welding is a commonly used industrial process. A low efficiency of the inverter, transformer and rectifier lead to high operation costs and a bulky cooling system. This work investigates a new transformer with integrated synchronous rectification that significantly increases the system efficiency and decreases system size and weight, and therefore offers lower costs for energy, the cooling system, transformer and rectifier. A modulation scheme for the synchronous rectifier is proposed and the high efficiency and the thermal behavior of the transformer are presented.