TechnicalProposalof200kWsolidstateHFWelder.docx
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TechnicalProposalof200kWsolidstateHFWelder.docx
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TechnicalProposalof200kWsolidstateHFWelder
厶-
IA四方
TechnicalProposal
of
200kWSolidStateHFWelder
BaodingSifangSanyiElectricCo.,Ltd.
2015.4
I.TECHNICALDESCRIPTION
CATALOGUE
1.featuresofnewgenerationh.f.solidstatewelder
2.MODELINSTRUCTIONSFORSOLIDSTATEh.F.WELDER
3.WORKINGPRINCIPLEOFSOLIDSTATEH.F.WELDER
3.1MaincircuitstructureofsolidstateH.F
.welder
3.2WorkingprincipieofsolidstateH.F
.welder
4.technicalPARAMETERSof200KWSOLIDSTATEH.F.WELDER
5.CORETECHNICALINSTRUCTIONSOFCONTROLANDPROTECTION
6.mainpartslistforsolidstateH.f.welder
n.COMPOSITIONANDBRIEFINTRODUCTIONFORSOLIDSTATEH.F.WELDER
1.eQUipmentcomposition
2.briefintroductionforsolidstateh.f.welder
m.SUPPLYLIST
IV.REQUIREMENTSFOREQUIPMENTOPERATION
1.environmentrequirements
2.poWERNETREQUIREMENTS
3.waterqualityrequirementsforexternalcirculationWATERPOOL
V.SUPPLYSCOPE
10
1.SUPPLYSCOPEFORSELLER
10
2.SUPPLYSCOPEFORBUYER
10
I.TechnicalDescription
1.FeaturesofnewgenerationH.F.solidstatewelder
1.1ThesolidstateH.F.welderadoptsGermanyIXYScompanyIXFN38N100Q2
38A/1000Vhigh-powerMOSFETandDSEI2>61-12B60A/1200Vrapidrecoverydiodetocomposeseriestypeinvertiblecircuit.
1.2ThesolidstateH.F.welderadoptsmodularizationdesignwithmorecompact
structurewhichmakesmaintenanceandhigh-powerrealizationmucheasier.
1.3Ithasparticulartechnologyofbridge-dividedover-currentprotectionthat
guaranteesequipmentsafety.
1.4Itcombinesinternationaladvaneedcontrolmethodofsameproducts,adopts
advaneedtechnologieslikefixedanglephase-lockingcontrol,upperfrequencylimit/lowerfrequencylimitlock-lostprotectionandetc.Withthesetechnologies,theequipmentsrunmorestably,moreefficiently,moreaccurateandeffectiveprotectionstotheinductorshort-circuitandopen-circuitmalfunctionduringpipeweldingproduction.
1.5Line-inendofsolidstateH.F.welderdoesnotneedstep-up/step-downrectifier
transformer,comparedwithvacuumtubewelderandparalleltypewelder;ithassignificantenergy-savingeffects(Undersameweldingcondition,energy-saving
>30%comparedwithvacuumtubewelder).
2.ModelinstructionsforsolidstateH.F.welder
3.WorkingprincipleofsolidstateH.F.welder
3.1
.welder
MaincircuitstructureofsolidstateH.F
SolidstateH.F.weldermaincircuitstructureisasfollowsfig.1;itisatypicalAC-DC-AC
variablefrequencystructure.Rectifieradopts3-phasebridgestylethyristorphase-controlrectifiercircuit,DCsideadoptsinductor,capacitortocomposeLCfilterwhichmeettheworkingrequirementsofvoltagetypeinverter.Thevoltagetypeinverter
adoptsmodularizationparallelstructuretoextendpowersupplypower,eachinvertermoduleissinglephaseMOSFETbridgestylecircuitconnectedwithseriesresonancetankcircuitbyH.F.matchingtransformer.Ononehand,thematchingtransformerrealizespowercombinationandimpedaneematching;ontheotherhanditrealizeselectricisolationofloadandpowersupply.Toputeffectiveandswiftprotectiononover-currentmalfunctionofvoltagetypeinverter,ourcompanyintroducesspecialandstableover-currentprotectioncircuitwhichguaranteessafeandstablerunningof
inverter.
.welder
Fig1CircuitstructureofsolidstateH.F
3.2WorkingprincipleofsolidstateH.F.welder
VoltagetyperesonanceinverteralsocalledseriesconnectiontyperesonanceinverteristhemostcriticalpartofthewholesolidstateH.F.powersupply;fig2showsthestructure,outputvoltageandcurrentwaveofinvertermodule.BycontrollingconnectionanddisconnectionalternativelyofMOS1&3,MOS2&4,theseriesconnectiontypeinverter
outputvoltageuhisclosetosquare-wave,duetotheinverteroutputvoltagefrequencyis
loadcurrentihisclosetosinewaveform.
Fig2Voltagetyperesonanceinvertercircuitstructureandoutputwaveform
Seriesconnectionresonanceinvertertypicalworkingstatecanbedividedintothree
types:
sensibility,resistiveleakage,capacitive.Fig3showsseparatelythethreeworking
status'inverteutputvoltage,currentandexperimentwaveforms.
Fig3Seriesconnectionresonanceinverteroutputwaveforms
Whenseriesconnectionresonanceinverterworksatsmallsensitivitystatus(fig3a),inverter'sworkingfrequencyishigherthaninherentresonancefrequencyofresonance
'sstartupiszerovoltage(ZVS),
tankcircuitalittlebit,i.e.loadcurrentihlagtoloadvoltageuhaelectricangleW.Nowcurrent-exchangeofinverterhasseveralfeatures:
1)Partzerocurrent(ZCS),theoreticallythewastageofthepart'startupiszero;2)Part'sshutdowniszerovoltage,non-zerocurrent,butduetosmallcurrentwhenpart'sshutdown,pluszerovoltagecurrent-exchange(ZVS),sopart'shutdownwastageissmalltoo;3)circuitstrayinductaneehassmalleffectoninvertercurrent-exchange;4)current-exchangehasnorequirementonbackwardrecoveryfeaturesofinverseparalleldiode,thepartssufferverysmallsurgeimpactwhencurrent-exchanging.
Whenseriesconnectionresonanceinverterworksatcapacitivestatus(fig3b),inverterworkingfrequencyislowerthaninherentresonancefrequencyofresonancetankcircuit
alittlebit,i.e.loadcurrentiHadvaneetoloadvoltageuhaelectricangleW.Now
current-exchangeofinverterhasseveralfeatures:
1)Part'shutdowniszerovoltage
(ZVS),zerocurrent(ZCS),theoreticallythewastageofthepart
'sshutdowniszero;2)
Part'startupishighvoltage,largecurrent,sopart'startupwastageisverybig;3)
circuitstrayinductaneehasstrongeffectoninvertercurrent-exchange;4)backward
recoverycurrentofinverseparalleldiodeofMOSyieldstrongvoltagecurrentoscillation,
thepartssufferverystrongsurgeimpactwhencurrent-exchanging,itthreatenspower
partsafetyrunningseverely.
Whenseriesconnectionresonanceinverterworksatresistiveleakagestatus(fig3c),it
workingfrequencyequalsinherentresonancefrequencyofresonancetankcircuit,i.e.
loadcurrentiHhasthesamephasepositionwithloadvoltageuh.Theoreticallythe
resistiveleakagestatusisthebestworkingstatus,butactuallyduetotheeffectsof
deadzoneperiodandresistanee&capacitaneeabsorptioncircuit,inverter
current-exchangepart'sworkingstatusisnotingoodcondition,alsoloadfluctuation
makesinverterdeviatetocapacitiveworkingstatuseasily,itthreatens
stableand
saferunningofinverter.
Fromtheanalysisaboveweknowthatthebestworkingstatusofseries
connection
resonanceinverterissmallsensitivitystandardresonancestatus.
Besides,comparedwithothercompany'印arallelconnectionresonance
H.F.power
supply,ourcompany'sseriesconnectionresonanceH.F.powersupplypartsnotonlyhas
smallswitchwastageandhighpowersupplyefficiency,butalsohasmuchbetter
protectiontovariousmalfunctionsofresonancetankcircuit.
4.Technicalparametersof200kWsolidstateH.F.welder
①Designedparameters
Nominalpower:
200kW
RatedDCpower:
Pd=240kW
RatedDCvoltage:
UdN=450V
RatedDCcurrent:
IdN=530A
Powersupplyefficiency:
n》85%
Outputpower:
Pout>200kW
Designedfrequency:
f=300~350kHz
MOSFETinverter:
60kWM
Tankcircuitoutputmode:
noweldingtransformeroutput,secondaryresonance
②Powerdistributionrequirements
Nominalpower:
200kW
RatedDCpower:
Pd=240kW
Line-inpowerfactor:
COS©少0.
Powerdistributioncapacity:
S270k#A
Powersupplyvoltage:
3-phase380V/50Hz
Line-incurrent:
I=430A
2
Line-incable:
eachphaseadopts185mmcoppercable,3-phase4-line
③Water-watercoolingsystem
Withtheadoptionofwater-waterheatexchanger
Pressureofinnercirculationwater:
0.15~0.25MPa
3
Flowofinnercirculationwater:
25m/h
Temperatureofinnercirculationoutwater:
<403
Temperatureofinnercirculationbackwater:
N53
2
Heatexchangerarea:
为m
3
Flowofexternalcirculationwater:
25m/h(providedbyuser)
Temperatureofexternalcirculationinletwater:
<353
2
Pressureofinletwater:
0.20〜0.3MPa(approximately2.0〜3kg/cm)
5.Coretechnicalinstructionsofcontrolandprotection
5.1SolidstateH.F.welderadoptsthemostadvaneedfixed-angelphase-locking
controltechnique,inverterworkingstatusdonotchangeasloadtankcircuitchange,whichkeeptheworkatthebestsmallsensitivityresonancestatusallthetime,welderworksstablywithhighefficiency.
5.2SolidstateH.F.welderhasadvaneedfunctionslikehigh/lowlock-lostprotection,
frequencyupperlimit/lowerlimitprotection,invertover-current,tankcircuit
over-voltageandetc.Alsomoreaccurateandefficientonopen-circuit,
short-circuit,arcingofinductormalfunction,itguaranteeswelderstablerunning.
5.3Besidesregularprotections,eachinverterbridgeadoptsmultipleprotections,
suchasDCsideover-current,ACsideover-current,ACsideover-voltageandetc.
Itrealizesprotectionredundancy,guaranteesinveriersaferunning.
5.4Rectifiersidecontrolcircuitadoptssinglechiptechnologywhichsolvesautomatic
phase-recognizesuccessfully,i.e.norequirementson3-phasepowersupply
inputline;thyristortriggercircuitadoptsalldigitalequalintervaltriggering,it
reducesnon-characteristicsharmonicsfurthestandpowernetpollution.
5.5Rectifiercontrolcircuithassoftstartup,softstopfunctionwhichprevents
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