500kw Solid State High Frequency Tube Welder for ERW Tube Mill Line

Overview

Basic Info.

Model NO.	GGP-500/0.25-HC
Frequency Range	High Frequency
Electric Current	DC
Model	Ggp-500/0.25-Hc
Working System	Continuous Working System
Mosfet Inverter	100kw×5
Welding Material	Low Carbon Steel
AC Input	3-Phase AC 380V 50/60Hz
Output Power	Pout>500kw
Electrical Efficiency	≥85%
Frequency Scope	200-250kHz
Rated DC Current	1150A
Rated DC Voltage	450V
Transport Package	Plywood Case with Dust Proof Bag
Specification	Open top container
Trademark	SANZHENG
Origin	China
HS Code	8515219100
Production Capacity	25 Units/Year

Product Description

Product composition

500kW Solid State High Frequency Tube Welder for ERW Tube Mill Line

Description	Composition	Qty.
GGP-500/0.25-HC 500kW Solid state high frequency welder (1 unit)	Switching rectifying unit	1
	Inverter output unit	1
	Control desk	1
	2-D positioning table	1
	Water-water cooler	1
	Air conditioner	1
	Optical fiber	1

Product Introduction

Switching rectifying unit

The integrated design of the switch and the rectifier part, in addition to the function of the switch cabinet, also has the rectifying control function of the solid-state high frequency welder.
1) Installed 3-phase full-controlled thyristor rectification bridge to realize power adjustment of the high frequency welder.
2) Installed flat-wave reactor, flat-wave capacitor and filter to improve the flat-wave coefficient.
3) Protection reactor, ammeter, and current hall sensor are installed to protect and monitor the inverter bridge.
4) Siemens S7-1200 PLC is installed to realize power logic control and Ethernet communication functions.

Inverter output unit

The inverter output unit realizes the integrated design of resonant inverter and series resonant tank circuit, with the advantages of compact structure, high efficiency, convenient maintenance, low failure rate, high efficiency and energy saving.

1. The inverter part is composed of MOSFET single-phase inverter bridges in parallel. The inverter bridge is designed to be 100kW, which completes the power superposition in a modular way.
2. The matching transformer is used to complete the power synthesis, with adopt of the secondary low-voltage resonance and no welding transformer output mode. The tank circuit resonant capacitor (low voltage) and steel tube Vee type inductor resonate directly, to realize the power transmission through the output of the induction welding unit.
3. Use a sealed cabinet and equipped with air conditioners installed on the top.

Control desk

1) Adopt stainless steel operation penal with beautiful appearance and easy to clean.
2) Add touch screen protection cover to improve the service life of touch screen.
3) The touch screen of the control desk has data recording function for important parameters and information, which is convenient for historical query. Meanwhile, it has visual data record, which is convenient for analysis and viewing the status information of the equipment.
4) It has the functions of remote operation, power regulation, state monitoring and fault diagnosis of HF welder.
5) Ethernet interface is reserved to facilitate the user's function expansion and realize remote monitoring and information collection.
6) The function can be added and expanded according to the actual needs of users.

2-D positioning table

It is used for fixed installation of welder and position adjustment of the work coil.
2-D positioning table is adopted: manual adjustment in front / back, left / right direction, stable and reliable adjustment, so as to ensure that the work coil is always in the best welding position.

Water-water cooler

The water-water cooler completes the cooling of heating components such as the rectifying bridge, flat-wave reactor, inverter bridge, and resonance tank circuit, and is designed with water temperature indication and protection. Adopt water-water heat exchanger. The characteristics are:

1. Purified water circulates, the water quality is clean without scale in pipelines, which greatly reduces the operation faults of the equipment..
2. Closed cycle circulation, no impurities entering, no moss, the pipeline will not be blocked.
3. Small size, good integrity and convenient installation.
4. Closed water circulation with little water consumption.
5. It can avoid the malfunction caused by condensation water in summer.
6. Small size water storage tank, and antifreeze can be used in winter to avoid water failure caused by freezing.
7. It is more economic than an air-water cooler.
8. Adopt stainless steel water tank and in-line pump.

Measures for high efficiency and energy saving

1) PSM technology
With the latest PSM inverter control technology, when welding steel pipes of different specifications, the welder can ensure a constant DC voltage of 450V and output power continuously adjusted. At this time, the welder has the highest grid side power factor, the minimum input current and the best welding efficiency.
2) Integrated inverter bridge
Adopt the optimized integrated inverter bridge with small stray loss.
3) Welding frequency optimization
With optimal design of resonance tank circuit, the frequency of the welder is 20% - 30% higher than the original design and effectively improve the welding efficiency.
4) Welding process optimization
According to the tube mill specifications and tube type, optimize the structural design of the output lead.

Technical advantages
1) Energy saving - PSM technology effectively solves the load matching problem of solid-state HF welders and lays the foundation for high efficiency and energy saving.
2) Reliability - the Integrated inverter bridge significantly improve the reliability and stability of the solid-state HF welder.
3) Intellectualization - Full digital control system improves the automatic management level of solid-state HF welder.Technical parameters:

1	Nominal power	500kW
2	Rated DC power	Pd=500kW
3	Rated DC voltage	UdN=450V
4	Rated DC current	IdN=1150A
5	Whole efficiency	η≥85%
6	Output power	Pout>500kW
7	Designed frequency	f=200~250kHz
8	MOSFET inverter	50kW×5
9	Line incoming cable	240mm2×2 pc/phase

Company Profile

FAQ

Q1:Are you a trading company or Manufacturer?
A:We are manufacturer with independent research and development capability, supplying products to our clients all overthe world.

Q2. Manufacturing delivery time?
A:30 days since receiving of down payment.Q3. How to solve the malfunction occurred during operation?
A:You can send the malfunction information to us by email, or leave message to us on WeChat or WhatsApp.
Q4. Whether the online commissioning or technical support will be available?
A:Yes, we can provide online guidance and technical support for commissioning through WeChat or WhatsApp.Q5. Can you provide the onsite service if we needed?
A:Yes, we can provide the onsite service if you needed. The corresponding expenses will be borne by the customer.Q6. Payment terms?
A:30% by T/T as down payment, 70% by T/T before shipment.