A welding current source for providing a welding current and a welding voltage at an output in order to carry out an arc welding process includes an input-side rectifier, an inverter, which is operated with a switching frequency, a transformer having a primary winding and at least two secondary windings, at least two rectifiers arranged between the secondary windings and the output, and at least one capacitor and one load resistor at the output. At least one current-limiting reactor is arranged on the second secondary winding and the load resistor for discharging the capacitor, which can be charged by the current-limiting reactor, the current-limiting reactor, and the capacitor are dimensioned in such a way that the maximum value of the no-load voltage at the output is greater than the voltage corresponding to the transmission ratio of the primary winding to the secondary winding of the transformer.

A welding-type power supply including a balanced plate rectifier to rectify high frequency alternating current from one or more transformers. The balanced plate rectifier includes an output terminal symmetrically connected to the plates of the plate rectifiers. The impedance between the output terminal and each plate is substantially equal.

High-frequency transformers using solid wire for welding-type power supplies are disclosed. An example welding-type power supply transformer includes: a first coil assembly comprising a first plurality of turns of a first solid wire wrapped around a first bobbin to form a first single-layer primary winding, and a second plurality of turns of a second conductor over the first plurality of turns to form a first single-layer secondary winding; a second coil assembly comprising a third plurality of turns of a second solid wire wrapped around a second bobbin to form a second single-layer primary winding, and a fourth plurality of turns of the second conductor over the third plurality of turns to form a second single-layer secondary winding; and first and second cores disposed at least partially within the first and second bobbins.

A method and apparatus for providing welding type power supply includes a power circuit and a control circuit. The power circuit receives input power and provides welding type power to a welding output. The power circuit includes a transformer having a primary winding and a secondary winding. The secondary winding is in electrical communication with the welding output. The control circuit is connected to control the power circuit. The transformer includes a bobbin with the primary winding and the secondary winding wound thereon. The bobbin can includes vents to allow air flow into the bobbin. A winding separator can be disposed between the primary and secondary windings.

A flat, electrically and thermally conductive flat surface group is formed in the common connection region 32 of the secondary coil 13. The flat conductive surface group is directly and mechanically joined to the connecting surfaces of the first conductor plate 42, the second conductor plate 44, and the third conductor plate 46, respectively. The first conductor plate 42, the second conductor plate 44, and the third conductor plate 46 cover the entire common connection region 32. The annular first conductor plate 42 occupies the maximum area. The refrigerant can be circulated in the annular cavity provided inside the first conductor plate 42 to efficiently cool the whole.

High-frequency transformers using solid wire for welding-type power supplies are disclosed. An example welding-type power supply transformer includes: a first coil assembly comprising a first plurality of turns of a first solid wire wrapped around a first bobbin to form a first single-layer primary winding, and a second plurality of turns of a second conductor over the first plurality of turns to form a first single-layer secondary winding; a second coil assembly comprising a third plurality of turns of a second solid wire wrapped around a second bobbin to form a second single-layer primary winding, and a fourth plurality of turns of the second conductor over the third plurality of turns to form a second single-layer secondary winding, the first single-layer primary winding being in parallel with the second single-layer primary winding, wherein the second conductor comprises at least one of an obround cross-section, a rectangular cross-section, or a rectangular cross-section having radiused corners, the second plurality of turns have a transverse cross-section of the second conductor that is constant along at least the portion of the second conductor comprising the second plurality of turns, and the fourth plurality of turns have a transverse cross-section of the second conductor that is constant along at least the portion of the second conductor comprising the fourth plurality of turns; and first and second cores disposed at least partially within the first and second bobbins.

A welding current source for providing a welding current and a welding voltage at an output in order to carry out an arc welding process includes an input-side rectifier, an inverter, which is operated with a switching frequency, a transformer having a primary winding and at least two secondary windings, at least two rectifiers arranged between the secondary windings and the output, and at least one capacitor and one load resistor at the output. At least one current-limiting reactor is arranged on the second secondary winding and the load resistor for discharging the capacitor, which can be charged by the current-limiting reactor, the current-limiting reactor, and the capacitor are dimensioned in such a way that the maximum value of the no-load voltage at the output is greater than the voltage corresponding to the transmission ratio of the primary winding to the secondary winding of the transformer.

An electromagnetic pulse welding coil includes a first conductive region and a second conductive region. The second conductive region is assigned to a remainder of the coil and has a low current density. The first conductive region is configured for generating a higher current density than the second conductive region. The first conductive region is detachably connected to the remainder of the coil using a detachable connection. The electromagnetic pulse welding coil is planar in design and is cut out of a metal plate.

An electromagnetic pulse welding coil includes a first conductive region and a second conductive region. The second conductive region is assigned to a remainder of the coil and has a low current density. The first conductive region is configured for generating a higher current density than the second conductive region. The first conductive region is detachably connected to the remainder of the coil using a detachable connection. The electromagnetic pulse welding coils is planar in design and is cut out of a metal plate.

A high-frequency transformer for use in welding-type power supplies. The high-frequency transformer includes insulated winding wire which may allow for compressed turns. Compressed turns may result in lower leakage inductance and physically smaller transformers.