Welding Machine Fail in Dusty and Corrosive Areas

Electrical engineering root cause analysis (RCA) related to welding machines and their poor availabilities and often fail.

Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.

Welding Machine Fail

Motor Generator Welding Sets, (MGWS) and even Rectifier Welding Sets (RWS) of no moving parts fail often in dusty and corrosive areas.

Author Solution

The author got the RWS internals housed in a shop-made below given features tank:

1. Radiators akin to transformers fitted oil circulating and heat radiating tubes
2. Inside and outside epoxy painted
3. Silica gel breather mounted and transformer oil filled

In addition, he ensured well-crimped tinned ‘hole drilled to suit terminal’ copper lugs to the Al welding cables, and well-tightened cable lugs by strict supervision to form a habit.

Gone are terminal burns, charred cable insulation, etc. Consequently, all welding machines were trouble-free forever. 

Added ‘snail conveyor belt covers’ as in TEFC motors to MGWS, and strictly ensured their cleaning and return to the workshop immediately after corrosive areas job completions. MGWSs too serve trouble-free forever.

Author: S. Raghava Chari

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