Duty cycle of welding machine

A welder's duty cycle refers to the percentage of time within a specific time period (usually 10 minutes) that the welder can operate continuously without overheating or damage, typically expressed as a percentage. It is a key parameter for measuring a welder's continuous operating capacity and directly impacts its efficiency and lifespan.

Key Points:

Definition and Calculation

Duty cycle = (Actual welder operating time / Total cycle time) × 100%.

For example, if a welder operates for 6 minutes and rests for 4 minutes within 10 minutes, its duty cycle is 60%.

Industry Standard Cycle

The internationally accepted standard cycle is 10 minutes (some older equipment may use different cycles). Any cycle exceeding this time requires shutdown and cooling to prevent insulation aging or component damage.

Relationship with Welding Current

Inversely proportional: The higher the duty cycle, the lower the maximum output current allowed by the welder (and vice versa). Nameplate markings: Welding machine parameters are often marked with something like "300A @ 60%," meaning it can output 300A at a 60% duty cycle. If 100% duty cycle is required, the current must be reduced.

Application Impact

High duty cycle requirements (such as automated welding): Select an industrial-grade welder with a duty cycle ≥ 60%.

Intermittent work (such as repairs): A home or light-duty welder (30%-40% duty cycle) will suffice.

Overheat Protection Mechanism

Modern welding machines are typically equipped with temperature sensors or automatic current reduction functions, which force a shutdown when overloaded to protect core components (such as IGBT modules).

Additional Notes:

Test Conditions: Duty cycle must be measured at a standard ambient temperature (below 40°C). High temperatures will reduce actual performance.

Difference from "duty cycle": In Chinese terminology, "duty cycle" is an outdated term; it is now generally referred to as "duty cycle," but the meaning is the same.

Understanding this parameter helps in making reasonable selection and avoiding equipment failure or degradation of welding quality due to overload.