Е-Публикации
Технически университет - София

Abstract: With the increasing demand for energy efficiency and sustainable manufacturing practices, arc welding is undergoing a significant transformation through the implementation of modern inverter technologies. This article reviews the principles, architecture, and advantages of energy-optimized inverter systems, focusing on their role in increasing efficiency, arc stability, and weld quality. Comparative analyses between traditional transformers and modern high-frequency inverter power sources are presented, considering reduced energy consumption, improved mobility, and extended digital control capabilities. In addition, innovative control methods using pulse-width modulation (PWM), the impact of changes in heat input on the metal structure, and the potential for integration of inverter systems in the Industry 4.0 concept are discussed. The study aims to highlight the strategic importance of energy optimization in modern welding production and to outline the prospects for future technological improvements.

References

1. Q. Wang, W. Jiao, P. Wang and Y. Zhang, "Digital Twin for Human-Robot Interactive Welding and Welder Behavior Analysis," in IEEE/CAA Journal of Automatica Sinica, vol. 8, no. 2, pp. 334-343, February 2021, doi: 10.1109/JAS.2020.1003518
2. Jaroslav, Dudrik & Pastor, Marek & Lacko, Milan & Žatkovič, Róbert. (2017). High-Frequency Soft-Switching PWM DC-DC Converter with Active Output Rectifier Operating as a Current Source for Arc Welding Applications. Electric Power Components and Systems. 45. 1-11. 10.1080/15325008.2017.1291770.
3. Kim, Changjong & Han, Sung & Seo, Bo & Bae, Inyeong & Kim, Duckbong & Kim, Seok & Cho, Young Tae. (2025). Architecture Development of Digital Twin-Based Wire Arc Directed Energy Deposition. International Journal of Precision Engineering and Manufacturing-Green Technology. 12. 10.1007/s40684-025-00747-8.
4. Benjamin Maschler, Dominik Braun, Nasser Jazdi, Michael Weyrich, "Transfer learning as an enabler of the intelligent digital twin," Procedia CIRP, Volume 100, 2021, Pages 127-132, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2021.05.020.
5. Yannik Hahn, Robert Maack, Guido Buchholz, Marion Purrio, Matthias Angerhausen, Hasan Tercan, Tobias Meisen, "Towards a Deep Learning-based Online Quality Prediction System for Welding Processes," Procedia CIRP, Volume 120, 2023, Pages 1047-1052, ISSN 2212-8271, https://doi.org/10.1016/j.procir.2023.09.123.
6. Lei, Zhongcheng & Zhou, Hong & Dai, Xiaoran & Hu, Wenshan & Liu, Gp. (2023). Digital twin based monitoring and control for DC-DC converters. Nature Communications. 14. 10.1038/s41467-023-41248-z.
7. Minglei You, Qian Wang, Hongjian Sun, Iván Castro, Jing Jiang, "Digital twins based day-ahead integrated energy system scheduling under load and renewable energy uncertainties," Applied Energy, Volume 305, 2022, 117899, ISSN 0306-2619, https://doi.org/10.1016/j.apenergy.2021.117899.
8. A. Castellani, S. Schmitt and S. Squartini, "Real-World Anomaly Detection by Using Digital Twin Systems and Weakly Supervised Learning," in IEEE Transactions on Industrial Informatics, vol. 17, no. 7, pp. 4733-4742, July 2021, doi: 10.1109/TII.2020.3019788
9. Jalal Taheri Kahnamouei, Mehrdad Moallem, "Advancements in control systems and integration of artificial intelligence in welding robots: A review," Ocean Engineering, Volume 312, Part 3, 2024, 119294, ISSN 0029-8018, https://doi.org/10.1016/j.oceaneng.2024.119294.
10. Fei Tao, Qinglin Qi, Lihui Wang, A.Y.C. Nee, "Digital Twins and Cyber–Physical Systems toward Smart Manufacturing and Industry 4.0: Correlation and Comparison," Engineering, Volume 5, Issue 4, 2019, Pages 653-661, ISSN 2095-8099, https://doi.org/10.1016/j.eng.2019.01.014.
11. Z. Zlatev, T. Georgieva, A. Todorov, and V. Stoykova, “Energy efficiency of IoT networks for environmental parameters of Bulgarian cities,” Computers, vol. 11, no. 5, p. 81, May 2022, doi: 10.3390/computers11050081.
12. G. Danailov Goranov, N. Dimitrov Madzharov and I. O. Kandov, "Resonant inverter with All Digital PLL control," 2016 International Conference and Exposition on Electrical and Power Engineering (EPE), Iasi, Romania, 2016, pp. 653-657, doi: 10.1109/ICEPE.2016.7781420.
13. N. Madzharov, R. Ilarionov and L. Petkov, "Experimental studies of a method of simultaneous contactless transmission of energy and information signals through a common inductive link," 2019 IEEE XXVIII International Scientific Conference Electronics (ET), Sozopol, Bulgaria, 2019, pp. 1-4, doi: 10.1109/ET.2019.8878648.

Issue

Copyright IEEE