In industry, for superior utilization of large capital equipment, a
single large-current high-power converter is desired to convert
electrical energy to a controlled high-intensity heat source to cater to
the dynamic requirement of several welding methods (e.g., welding,
hard-facing, gouging, weld overlay, etc.). The dynamic process behavior
of multi-input minimally semiautomatic or single-input manual processes
could follow either constant voltage (CV) or constant current (CC) arc
type. Due to completely different type of arc or load characteristics,
this article proposes a de-coupled control approach to guide the power
source to independently take care of each arc type. It proposes
feedforward control for CV arc type and robust second order sliding mode
control (SOSMC) approach for dynamically uncertain CC arc type for
manual welding. It further highlights that low-loss resonant or
soft-switching topologies are less compatible for decoupled control of
high-power loads with wide range impedance characteristics. For desired
energy efficiency of a full-bridge DC-DC converter for arc welding, this
article details that robustness features of SOSMC could be used for
superior component engineering that incur low power loss. Finally, this
article completely validates the proposed idea in a 1000A power
converter for both CC and CV arc types.