TechnicalProposalof200kWsolidstateHFWelder.docx

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