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High-Frequency Welding Machine for Tube Mill - Reliable China Suppliers & Factory Solutions
Working principle of solid-state high-frequency welding pipe equipment
High-frequency inverters are available in two types: series resonant and parallel resonant. However, pure parallel resonant inverters face challenges in high-frequency power applications, such as the inability to eliminate lead inductance effects, which limits their use in large-capacity high-frequency power systems. The series resonant inverter, also known as a voltage resonant inverter, operates under high-voltage conditions within the cabinet. This results in a loose internal layout, increased energy radiation, and potential high-voltage arcing or safety hazards. The third-generation all-solid-state welded tube power supply employs fast-recovery diodes IRFP460 and DSEI60-06A as main power components. Its circuit topology adopts a current-source-fed series-parallel configuration, combining the advantages of both series and parallel circuits while avoiding their drawbacks. Additionally, a specialized circuit topology eliminates switching losses in power electronic devices at high frequencies, thereby enhancing both efficiency and overall system reliability.
Solid state high frequency welding machine composition
| Name | Quantity | Remarks |
|---|---|---|
| Rectifier Cabinet | 1 unit | - |
| Inverter Cabinet | 1 unit | Air conditioner included |
| Speed Controller | 1 unit | Euro 590 |
| Wind and Water Exchange | 1 unit | - |
| Step-down transformer | 1 unit | - |
| Operating floor | 1 unit | - |
| Output busbar | 1 set | - |
Some remarkable features of the third generation solid-state high-frequency power supply
Simple circuit and easy installation:
The control wiring between the rectifier cabinet and the inverter cabinet is less than ten, randomly configured. The wiring between the rectifier power supply and the operation table is also very few.
Harmonic interference is small, does not pollute the power grid:
A number of well-matched filter networks are designed, and the isolation effect of the rectifier transformer makes the harmonic components of the solid-state power supply very small when running at full power. The power factor can reach more than 0.9.
No high voltage is safe, and the sensor is not easy to strike a spark on the steel pipe:
The special high frequency slot design parameters are used to obtain the appropriate output voltage on the inductor. The spark between the inductor and the steel pipe is avoided and the stability of the equipment is increased.
The efficiency is up to 85%, the energy saving is obvious, and the cooling water consumption is less:
The advanced zero-voltage zero-current switching (ZVZCS) technology eliminates switching losses in power devices.
List of main components
| Name | Model | Manufacturer | Remarks |
|---|---|---|---|
| MOSFET | IRFP460 | VISHAY Corporation (USA) | - |
| Fast Recovery Diode | DSEI60 | VISHAY Corporation (USA) | - |
| Resistance | - | Austria | - |
| Tank capacitance | - | National brand | hydrocooling |
| Filter capacitor | BSMJ | Zhejiang | - |
| Thyristor | KP mould | Jinzhou, Hunan | hydrocooling |
| PLC | LE series | Holliger | - |
| Human-computer interface | HT8701T | Honeywell | - |
| Switching Mode Power Supply | - | Taiwan Mingwei Company | - |
| Water cooling system | S-S series | self-control | - |
Frequently Asked Questions (FAQ)
What is the working principle of the third-generation solid-state high-frequency welding equipment?
It utilizes a current-source-fed series-parallel configuration powered by IRFP460 and DSEI60-06A fast-recovery components. This layout combines the safety benefits of series circuits and the efficiency of parallel circuits while eliminating high-frequency switching losses.
What components make up the complete solid-state high-frequency welding machine?
The complete configuration includes a Rectifier Cabinet, an Inverter Cabinet (with integrated air conditioning), a Speed Controller (Euro 590), a Wind and Water Exchange, a step-down transformer, an Operating Floor, and an Output Busbar.
How does this equipment avoid polluting the local power grid?
Through custom-designed filter networks and the physical isolation effect of the rectifier transformer, the harmonic components are kept extremely low during full-power operation, achieving a power factor of over 0.9.
Why is the inductor sensor safe from striking sparks on the steel pipes?
The system employs specialized high-frequency slot design parameters that optimize the output voltage directly on the inductor. This prevents spark-overs between the inductor and the steel pipe, ensuring high operational stability and safety.
What technologies contribute to the 85% energy efficiency of the welder?
The implementation of advanced Zero-Voltage Zero-Current Switching (ZVZCS) technology eliminates switching losses in the power electronic devices, resulting in up to 85% efficiency and reduced cooling water consumption.
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