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Thread: Adding Digital Generators to an Old Analogue TIG Welder

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    Supporting Member chy_farm's Avatar
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    Adding Digital Generators to an Old Analogue TIG Welder

    Adding Digital Generators to an Old Analogue TIG Welder-digital_mixtig_unit.jpg
    .
    Set up a couple of digital generators to my old analogue TIG welder this spring, in an attempt to optimize its wave forms of welding current, to help my self when I make some butt-welding to thinner aluminium sheets.

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    Supporting Member chy_farm's Avatar
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    chy_farm's Tools
    Here showing my old TIG welder;
    Adding Digital Generators to an Old Analogue TIG Welder-hitachi_adgp1.jpg

    The digital unit above is set up on the front panel;
    Adding Digital Generators to an Old Analogue TIG Welder-digital_mixtig_unit_set_up.jpg

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    Several logic-chips are placed on a small additional board, and is placed on the main circuit board of the welder;
    Adding Digital Generators to an Old Analogue TIG Welder-digital_mixtig_unit-2-.jpg

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    The default setting only provides the minimum duty ratio of welding pulse as 12.5%
    .
    Adding Digital Generators to an Old Analogue TIG Welder-dctig_analogue_10hz_minimum-duty_100a-5a.jpg
    .
    but I wanted smaller duty as small as down to 1.0% for each welding pulse frequency,
    showing one sample I got after this retrofit;
    .
    Adding Digital Generators to an Old Analogue TIG Welder-dctig_digital_10hz_1.0%25duty_100a-5a_2.jpg

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    This old welder has a pulse-range from nearly 0.5Hz up to 500Hz done by analogue frequency generator by default. This old set-up of analogue pulse is not replaced with the new, it can be used if I want.

    One of the features I love is that this new set-up can provide higher pulse frequency from 500Hz up to 900Hz, which I found useful in welding thinner steel sheet.
    The arc sometimes wonders when the welding amperage is set low, like 30A for welding current and 5A for base current.

    But I feel like this problem has nearly gone since I added this new digital generator by applying DC welding pulse frequency higher than 750Hz;
    .
    Adding Digital Generators to an Old Analogue TIG Welder-750hz.jpg
    .
    with this frequency the arc shows somewhat better stability to the aimed point.

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    Below is a default wave form of Alternative Current welding, aluminium for example, showing the minus peak as 45A besides overshoot.
    Output power is set to 50A for welding;
    Adding Digital Generators to an Old Analogue TIG Welder-nopulse_actig_50a-5a_cleaning%3D-5.jpg
    This shows the real welding power is a tad lower than the setting value.

    Here is another wave form attained with the same setting but the output power was set to 30A;
    Adding Digital Generators to an Old Analogue TIG Welder-nopulse_actig_30a-5a_cleaning%3D-5.jpg

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    chy_farm's Tools
    Now I'm going to replace the rectangular wave forms of the both sides (of plus and minus domains), with a couple of pulses of arbitrary frequencies given by this new addition;

    Adding Digital Generators to an Old Analogue TIG Welder-digipulse_650hz_20%25_mixtig_2hz_50%25_150a-5a_crater.jpg
    Replaced the rectangular wave with 650Hz pulses, setting power 150A for welding.

    Adding Digital Generators to an Old Analogue TIG Welder-digipulse_700hz_20%25_mixtig_2hz_50%25_170a-5a.jpg
    also with 700Hz pulses, setting power 170A.
    Attached Thumbnails Attached Thumbnails Adding Digital Generators to an Old Analogue TIG Welder-digipulse_750hz_20%25_mixtig_2hz_50%25_100a-5a.jpg  
    Last edited by chy_farm; 07-28-2020 at 05:43 PM.

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    Thanks chy_farm! We've added your Digital Generators for a Welding Machine to our Metalworking category,
    as well as to your builder page: chy_farm's Homemade Tools. Your receipt:


    Last edited by Jon; 07-29-2020 at 11:24 AM.

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    As far the schematic, I am thinking of asking a buddy who guides me to attain this job with a lot of information on welding machines if he gives me permission to open his schematic design of this unit.

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    A nice addition to your old welder. A You have indeed created a much easier to use welder for thinner materials. How does the overshoot work? I'm guessing that your initial arc will be a little bit easier to strike with your settings.

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