kWHFWelderTechnicalProposal.docx

kWHFWelderTechnicalProposal.docx

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kWHFWelderTechnicalProposal

TechnicalProposal

for

StraightSeamWeldingPipeProductionLine

100kWSolidStateWelder

CATALOGUE

1.TechnicalInstructions1

1.1FeaturesofnewgenerationH.F.solidstatewelder1

1.2ModelinstructionsforsolidstateH.F.welder1

1.3WorkingprincipleofsolidstateH.F.welder1

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

.Nowcurrent-exchangeofinverterhasseveralfeatures:

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

·Nominalpower:

100kW

·RatedDCpower:

Pd=120kW

·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

·Ratedpower:

3-phase380V/50Hz

·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