Circulation Soft Water Cooling System Solid State H.F. Tube Welder Production Line

Solid State H.F. Tube Welder Production Line With Circulation Soft Water Cooling System Equipment Making Line

Technological index

Power scope: 50kW-2000kW

Frequency scope: 100kHz-20000kHz

Rated DC voltage: 10000V-15000V

Power grid voltage: 220V~660V,50/60Hz,3-phase

Composition and Brief Introduction for Solid State H.F. Welder

The whole set of solid state H.F. welder is composed of switchgear rectifying cabinet, inverter output cabinet, connecting optical fiber, circulation soft water cooling system, central operation console, mechanical adjustment device.

1 Switchgear rectifying cabinet

Designed with integration of switchgear cabinet and rectifying part, except achieving switchgear cabinet functions, it also has rectifying control functions of solid state H.F. welders.

Installed line-in switch, line-in current meter, voltage meter (can be switched) and line-in voltage indication lamp;

Installed 3-phase full-controlled thyristor rectification bridge to realize power adjustment of the HF welder;

Installed flat-wave reactor, flat-wave capacitor and filter to improve the flat-wave coefficient.

2 Inverter output cabinet

The inverter part is consisted of MOSFET single-phase inverter bridge connected in parallel. The power of single-phase bridge is 120kW; the inverter bridge adopts the building block method to realize power superposition. Every piece of bridge plates is designed in the shape of a drawer, which is very easy to install and repair;

The matching transformer is adopted for power combination, also it adopts the output method by of secondary resonance and non-welding transformer, tank circuit resonance capacitor (low voltage) resonates with the inductor directly, and the output pole plate offers required power transmission for pipe welding;

Adopted sealed equipment case, installed with air conditioner.

3 Connecting optical fiber

Switchgear rectifying cabinet and inverter output cabinet are connected with optical fiber to make sure control system can not be disturbed by high frequency signal, which enhances the reliability of equipment.

4 Circulation soft water cooling system

Water-water cooling system adopts plate type heat exchanger for the cooling of switchgear rectifying cabinet, inverter output cabinet, resonance tank circuit etc with designing of indication and protection of temperature and water level.

5 Central operation console

It realizes the functions of remote operation, power adjustment, status monitoring and malfunction diagnosis for solid state H.F. welder.

Mounted with HMI composed of PLC and LCD touch screen, which is easy to be operated and monitored by user at site.

Installed with various AC and DC meters and operation buttons for the working status display for the welder.

6 Mechanical adjustment device

For inverter output cabinet installation and inductor position adjustment.

[Display instrument digitization]

The rectifying cabinet panel is equipped with a multi-function digital meter, which has three phase input line voltage, three-phase line current, power factor, reactive power, active power, power, DC voltage, DC current and other parameters, and can be controlled, displayed and recorded through communication far to the upper computer.

[Full digital rectifying control board]

The new generation of solid state welding machine, using the field programmable logic gate array (FPGA) main control chip, the main frequency up to 100M, 16 bit A/D conversion chip (the original control board using 8 bit A/D conversion chip), the high precision of the data resolution; the cancellation of all the adjustable potentiometers on the board (12 control potentiometers in the original control board), color touch screen control System and parameter setting, debugging and operation are simple and intuitive. All parameters in the rectifier board can be transmitted to the host computer for display and recording through communication. The unique parallel working mode of FPGA ensures that the modules of the program operate at high speed and independently. 

[All digital inverter control board]

The new generation of solid state high frequency welder has integrated the advanced control concept of similar products in the world. The field programmable logic gate array (FPGA) is used as the main control chip to realize the advanced control technology such as the fixed angle lock phase control, the upper / lower frequency locking protection and so on, which makes the equipment running more stable and more efficient. 

[Closed loop technology of speed power]

The new generation of solid-state high frequency welding machine is designed with the most advanced pulse shielding technology (PSM control technology). It can guarantee the best load matching state of the solid high frequency welding machine with the highest welding efficiency, the highest power factor and the lowest net side harmonic current.  The customer only needs to input the parameters of production specifications and wall thickness through the touch screen. The welding machine can automatically calculate the output power of the high frequency welding machine according to the speed of the car, reduce the waste of the steel pipe, improve the yield of the steel tube and the efficiency of the operator.

[Ethernet networking technology]

The distributed production line is constructed by Ethernet communication between rectifier cabinet and operation table. Compared with hard wire control, it has advantages of on-site wiring, simple and convenient, reducing customer costs and maintenance costs. Compared with MODBUS communication and DP communication, it has faster speed and stronger anti-interference ability. Data acquisition and recording can be carried out.

[Cloud control technology (optional)]

The cloud service module is selected, all data can be monitored and recorded remotely, and the production line can be controlled remotely. It is convenient for customers to conduct data analysis, product quality control, production scheduling and automatic control of higher requirements.