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1.4Technicalparametersof100kWsolidstateH.F.equipment4
1.5Coretechnicalinstructionsofcontrolandprotection6
1.6MainpartslistforsolidstateH.F.welder6
2.ComposingandBriefIntroductionforSolidStateH.F.Welder7
2.1Equipmentcomposing7
2.2BriefintroductionforsolidstateH.F.welder7
3.SupplyList9
4.RequirementsforEquipmentUsing10
4.1Environmentrequirements10
4.2Powernetrequirements10
5.Supplyingscope11
5.1Supplyingscopeforsupplier11
5.2Supplyingscopeforuser11
6.TechnicalDocumentsDelivery11
7.InstallationandCommissioning12
1.TechnicalInstructions
1.1FeaturesofnewgenerationH.F.solidstatewelder
1.1.1ThesolidstateH.F.welderadoptsGermanyIXYScompanyIXFN38N100Q238A/1000Vhigh-powerMOSFETandDSEI2×
61-12B60A/1200Vrapidrecoverydiodetocomposeseriestypeinvertiblecircuit.
1.1.2ThesolidstateH.F.welderadoptsmodularizationdesignwithmorecompactstructurewhichmakesmaintenanceandhigh-powerrealizationmucheasier.
1.1.3Ithasparticulartechnologyofbridge-dividedover-currentprotectionthatguaranteesequipmentsafety.
1.1.4Itcombinesinternationaladvancedcontrolmethodofsameproducts,adoptsadvancedtechnologieslikefixedanglephase-lockingcontrol,upperfrequencylimit/lowerfrequencylimitlock-lostprotectionandetc.Withthesetechnologies,theequipmentsrunmorestably,moreefficiently,moreaccurateandeffectiveprotectionstotheinductorshort-circuitandopen-circuitmalfunctionduringpipeweldingproduction.
1.1.5Speed-powerclosed-loopcontrolsystemwhichisanoptionalinstallationtouser,ithighlyimprovesweldingefficiencyandreducestechnicsadjustmentperiod.
1.1.6Line-inendofsolidstateH.F.welderdoesnotneedstep-up/step-downrectifiertransformer,comparedwithvacuumtubewelderandparalleltypewelder;
ithassignificantenergy-savingeffects(Undersameweldingcondition,energy-saving≥30%comparedwithvacuumtubewelder).
1.2ModelinstructionsforsolidstateH.F.welder
1.3WorkingprincipleofsolidstateH.F.welder
SolidstateH.F.weldermaincircuitstructureisasfollowsfig.1;
itisatypicalAC-DC-ACvariablefrequencystructure.Rectifieradopts3-phasebridgestylethyristorphase-controlrectifiercircuit,DCsideadoptsinductor,capacitortocomposeLCfilterwhichmeettheworkingrequirementsofvoltagetypeinverter.Thevoltagetypeinverteradoptsmodularizationparallelstructuretoextendpowersupplypower,eachinvertermoduleissinglephaseMOSFETbridgestylecircuitconnectedwithseriesresonancetankcircuitbyH.F.matchingtransformer.Ononehand,thematchingtransformerrealizespowercombinationandimpedancematching;
ontheotherhanditrealizeselectricisolationofloadandpowersupply.Toputeffectiveandswiftprotectiononover-currentmalfunctionofvoltagetypeinverter,ourcompanyintroducesspecialandstableover-currentprotectioncircuitwhichguaranteessafeandstablerunningofinverter.
Fig1CircuitstructureofsolidstateH.F.welder
VoltagetyperesonanceinverteralsocalledseriesconnectiontyperesonanceinverteristhemostcriticalpartofthewholesolidstateH.F.powersupply;
fig2showsthestructure,outputvoltageandcurrentwaveofinvertermodule.BycontrollingconnectionanddisconnectionalternativelyofMOS1&
3,MOS2&
4,theseriesconnectiontypeinverteroutputvoltageuHisclosetosquare-wave,duetotheinverteroutputvoltagefrequencyisnearbyresonancefrequencyofresonancetankcircuit,andnowtheinverteroutputvoltagefundamentalwavefromresonancetankcircuittoinverterhastheminimumimpedancevalue,themaximumimpedancevaluetootherhighharmonics,thereforeloadcurrentiHisclosetosinewaveform.
Fig2Voltagetyperesonanceinvertercircuitstructureandoutputwaveform
Seriesconnectionresonanceinvertertypicalworkingstatecanbedividedintothreetypes:
sensibility,resistiveleakage,capacitive.Fig3showsseparatelythethreeworkingstatus’inverteroutputvoltage,currentandexperimentwaveforms.
(a)smallsensitivitystatus(b)smallcapacitivestatus(c)resistiveleakagestatus
Fig3Seriesconnectionresonanceinverteroutputwaveforms
Whenseriesconnectionresonanceinverterworksatsmallsensitivitystatus(fig3a),inverter’sworkingfrequencyishigherthaninherentresonancefrequencyofresonancetankcircuitalittlebit,i.e.loadcurrentiHlagtoloadvoltageuHaelectricangle
.Nowcurrent-exchangeofinverterhasseveralfeatures:
1)Part’sstartupiszerovoltage(ZVS),zerocurrent(ZCS),theoreticallythewastageofthepart’sstartupiszero;
2)Part’sshutdowniszerovoltage,non-zerocurrent,butduetosmallcurrentwhenpart’sshutdown,pluszerovoltagecurrent-exchange(ZVS),sopart’sshutdownwastageissmalltoo;
3)circuitstrayinductancehassmalleffectoninvertercurrent-exchange;
4)current-exchangehasnorequirementonbackwardrecoveryfeaturesofinverseparalleldiode,thepartssufferverysmallsurgeimpactwhencurrent-exchanging.
Whenseriesconnectionresonanceinverterworksatcapacitivestatus(fig3b),inverter’sworkingfrequencyislowerthaninherentresonancefrequencyofresonancetankcircuitalittlebit,i.e.loadcurrentiHadvancetoloadvoltageuHaelectricangle
1)Part’sshutdowniszerovoltage(ZVS),zerocurrent(ZCS),theoreticallythewastageofthepart’sshutdowniszero;
2)Part’sstartupishighvoltage,largecurrent,sopart’sstartupwastageisverybig;
3)circuitstrayinductancehasstrongeffectoninvertercurrent-exchange;
4)backwardrecoverycurrentofinverseparalleldiodeofMOSyieldstrongvoltagecurrentoscillation,thepartssufferverystrongsurgeimpactwhencurrent-exchanging,itthreatenspowerpartsafetyrunningseverely.
Whenseriesconnectionresonanceinverterworksatresistiveleakagestatus(fig3c),it’sworkingfrequencyequalsinherentresonancefrequencyofresonancetankcircuit,i.e.loadcurrentiHhasthesamephasepositionwithloadvoltageuH.Theoreticallytheresistiveleakagestatusisthebestworkingstatus,butactuallyduetotheeffectsofdeadzoneperiodandresistance&
capacitanceabsorptioncircuit,invertercurrent-exchangepart’sworkingstatusisnotingoodcondition,alsoloadfluctuationmakesinverterdeviatetocapacitiveworkingstatuseasily,itthreatensstableandsaferunningofinverter.
Fromtheanalysisaboveweknowthatthebestworkingstatusofseriesconnectionresonanceinverterissmallsensitivitystandardresonancestatus.Ourcompany’ssolidstateH.F.powersupplycontrolscircuitbyaccuratefixedanglephase-lockwhichmakesinverterreachesthebestworkingstate.Besides,comparedwithothercompany’sparallelconnectionresonanceH.F.powersupply,ourcompany’sseriesconnectionresonanceH.F.powersupplypartsnotonlyhassmallswitchwastageandhighpowersupplyefficiency,butalsohasmuchbetterprotectiontovariousmalfunctionsofresonancetankcircuit.
1.4Technicalparametersof100kWsolidstateH.F.equipment
1.4.1Designedparameters
·
Nominalpower:
100kW
RatedDCpower:
Pd=120kW
RatedDCvoltage:
UdN=450V
RatedDCcurrent:
IdN=270A
Thewholeefficiency:
η≥85%
Outputpower:
Pout>100kW
Designedfrequency:
f=400~450kHz
MOSFETinverter:
60kW×
2
Tankcircuitoutputmode:
noweldingtransformeroutput,secondaryresonance
1.4.2Powerdistributionrequirements
Line-inpowerfactor:
COSφ≥0.85
Powerdistributioncapacity:
S≤140kVA
Powersupplyvoltage:
3-phase380V/50Hz
Line-incurrent:
I=220A
Line-incable:
eachphaseadopts95mm2coppercableparallelconnections,3-phase4-line
1.4.3Circulationsoftwatercoolingsystem(air-watercoolingsystem,GPKL-Ⅱ-0..35)
Coolingcapacity:
30100kcal/h
Outlettemperature:
≤40℃
Workingflux:
12m3/h
Workingpressure:
0.15Mpa
Watertankcapacity:
320L
Ratedpower:
pipepumpmotor2.2kW,spraypumpmotor0.75kW,fanmotor0.37kW
Noise:
≤85dB
Withwatertanklevelindicationandtemperaturedisplay,lowwaterleveland
over-temperatureprotectionfunction
Dimension:
1580×
1130×
1960mm
1.5Coretechnicalinstructionsofcontrolandprotection
1.5.1SolidstateH.F.welderadoptsthemostadvancedfixed-angelphase-lockingcontroltechnique,inverterworkingstatusdonotchangeasloadtankcircuitchange,whichkeeptheworkatthebestsmallsensitivityresonancestatusallthetime,welderworksstablywithhighefficiency.
1.5.2SolidstateH.F.welderhasadvancedfunctionslikehigh/lowlock-lostprotection,frequencyupperlimit/lowerlimitprotection,invertover-current,tankcircuitover-voltageandetc.Alsomoreaccurateandefficientonopen-circuit,short-circuit,arcingofinductormalfunction,itguaranteeswelderstablerunning.
1.5.3Besidesregularprotections,eachinverterbridgeadoptsmultipleprotections,suchasDCsideover-current,ACsideover-current,ACsideover-voltageandetc.Itrealizesprotectionredundancy,guaranteesinvertersaferunning.
1.5.4Rectifiersidecontrolcircuitadoptssinglechiptechnologywhichsolvesautomaticphase-recognizesuccessfully,i.e.norequirementson3-phasepowersupplyinputline;
thyristortriggercircuitadoptsalldigitalequalintervaltriggering,itreducesnon-characte