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Inverters are now designed for many different processes: SMAW, GTAW, FCAW, SAW, and are capable of operating in extreme environments. As the popularity and reliability of the inverter increased, the capabilities were expanded. Less space is needed and the inverter unit is easily moved around the job site. For example, a rectifier-based machine, could weigh as much as four times that of an inverter-based machine. The initial attraction of the inverter was its small sizeĪnd easy portability. Inverter power sources were first introduced into the Some of the advantages an inverter has are smaller magnetic components (chokes and transformers), higher efficiency, and a fast response to the welding arc. Traditional power sources operate at a line frequency of 50 or 60 Hz. Lincoln inverter-based welding power sources operate at frequencies above 20 kHz, whereas The smaller size of the components inside the inverter machine translate into less heat to dissipate and again, greater efficiency This means less power is needed for moving cooling air and, again, greater efficiency. Because the inverter is designed to inherently have low losses, smaller cooling fans are required. Shorter current paths translate to lower resistances and better efficiencies.
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The compact design and relatively small physical size of an inverter welder means shorter leads and cables (or even direct connections) between powerĬomponents. The energy needed for stick welding or for globular transfer welding processes is stored in capacitors allowing for smaller output chokes. Operating at higher frequencies than conventional welders, inverters require less output inductance for smooth operation. Copper has higher thermal and electrical conductivity compared to aluminum, which will minimize losses and maximize efficiency. The inverter's power electronic components have been carefully designed to reduce losses and extend operating life. A smaller coil translates to less wire wrapping around the core - less wire means fewer losses and greater efficiency. The inverter transformer coils are physically smaller than common transformers. This reduces the current losses resulting in lower idle currents in the supply conductors. Greater transformer efficiencies are realized through the use of ferrite cores in the inverter's power transformer. Inverters can also save money in energy costs over traditional-type power sources since:
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In addition, inverters offer high-quality, multi-process welding capabilities so that one machine can handle Stick, MIG, TIG, FCAW, arc gouging and even pulsing.
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Inverters are more portable and lighter weight than traditional transformer-rectifiers, making them easier to maneuver around the job site.
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Power source that increases the frequency of the incoming primary power, thus providing for a smaller size machine and improved electrical characteristics for welding, such as faster response time and more control.