The machine is designed to serve with an output of 250A. it has two pats which are the primary and secondary parts. The primary part, through which voltage is supplied to the machine has 180 turns which is made of 2mm² S.W.G 14 copper coil. The secondary part has 45 turns made of 4mm² S.W.G 8 copper coil.

Both turns are wound on separate limb of the laminated core. The voltage from primary turns flows to the secondary turn by induction.

The machine contain a power switch through which the machine can be switched on or off when connected to the power source. The indication light simply shows when the machine is on or off which is equally controlled by the power switch.

The fan connected to the machine helps in the looking of the temperature of the machine, it gets started once the machine is on.

The welding current is adjusted by varying the spacing between the primary and secondary windings when the cranks is rotated, clockwise the insulating block between the two winding moves down, the magnetic flux leakage and the inductive impedance are increased, thereby reducing the welding current in the secondary windings. Also as the insulating block is moved upward, away between the two turns, the magnetic flux leakage and the inductive impedance are brought down, causing the welding current to rise.

TABLE OF CONTENT

Title page/approval page

Certification

Dedication

Acknowledgement

Abstract

Table of content

CHAPTER ONE

1.0 Introduction

1.1 Aims/objective

1.2 Scope or Limitation

1.3 Definition of Terms

CHAPTER TWO

2.0 Literature Review

2.1 Transformer Design

2.2 Coil Design

2.3 Core Design

2.4 Equivalent Circuit of the Machine

2.5 Machine Design

2.6 Operation of Machine

2.7 Leakage flux Reduction

2.8 Specification from Design

CHAPTER THREE

3.0 Construction

3.1 Lamination

3.2 Transformer former

3.3 Copper coil

3.4 Insulating Materials

3.5 Methodology

3.6 Casing

3.7 Coupling

3.8 Electrical Holder

CHAPTER FOUR

4.0 Testing and Finding

4.1 Open-Circuit Test

4.2 Short-Circuit Test

4.3 Test Analysis

4.4 Conditions for Operation

4.5 Cost Analysis

CHAPTER FIVE

5.0 Conclusion

5.1 Recommendation

REFERENCES

CHAPTER ONE

1.0 INTRODUCTION

The Arc welding machine is the type that uses an electric power as an input, which is being supplied through the primary and then transferred to the secondary winding by induction which can the be used to carry out welding work by connecting to the output terminal the welding cables.

The output of the machine is designed in a way that it can be varied by adjusting the crank of the machines in clockwise or anti-clockwise direction in either to increase or decrease the output current respectively depending on the size of the material it is to be used on.

AIMS/OBJECTIVES

This group agreed in bringing ideals together as one body to construct a functional 250Amp Arc welding machine, which will be fir in both industrial and agricultural field.