Analysis of an inverter-supplied multi-winding transformer with a full-wave rectifier at the output

Abstract This paper deals with the magnetic analysis of an inverter-supplied multi-winding transformer frequently used in resistance spot welding applications. The basic structure of the analyzed system consists of an inverter, a single-phase transformer with two secondary windings and a full-wave rectifier mounted at the output of the transformer, which assure a very short rise time of the welding current. The disturbing current spikes often appear in the transformer's primary in the steady-state operation, which can activate the over-current protection switch-off of the system. The results of numerical analysis performed on the nonlinear model of the discussed system have shown that very strong magnetic saturation of the transformer's iron core, caused by the interaction among the different ohmic resistances of secondary windings and different characteristics of the output rectifier diodes, provokes unwanted current spikes. Magnetic saturation could be efficiently eliminated using very simple passive method proposed in this paper. All findings are confirmed by systematic analysis numerically and experimentally.