TechnicalProposalfor500kWsolidstateHFWelder

1、Technical P roposalof500kW Solid State HF WelderBaodi ng Sifa ng Sanyi Electric Co., Ltd.2015.4Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal1I . TECHNICAL DESCRIPTIONCATALOGUE1. FEATURES OF NEW GENERATION H.F. SOLID STATE WELDER2. M ODEL INSTRUCTIONS FOR

2、SOLID STATE H.F. WELDER3. WORKING PRINCIPLE OF SOLID STATE H.F. WELDER3.1 Mai n circuit structure of solid state H.F.welder3.2 Work ing prin ci pie of solid state H.F.welder4. TECHNICAL PARAMETERS OF 500KW SOLID STATE H.F. WELDER5. CORE TECHNICAL INSTRUCTIONS OF CONTROL AND PROTECTION6. MAIN PARTS L

3、IST FOR SOLID STATE H.F. WELDERn . COMPOSITION AND BRIEF INTRODUCTION FOR SOLID STATE H.F. WELDER1. EQUIPMENT COMPOSITION2. BRIEF INTRODUCTION FOR SOLID STATE H.F. WELDERm . SUPPLY LISTIV . REQUIREMENTS FOR EQU IP MENT OP ERATION1. ENVIRONMENT REQUIREMENTS2. poWER NET REQUIREMENTS3. WATER QUALITY RE

4、QUIREMENTS FOR EXTERNAL CIRCULATION WATER POOLV . SUPPLY SCOPE10101. SUPPLY SCOPE FOR SELLER102. SUPPLY SCOPE FOR BUYER10Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal1Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop os

5、al1G GP H Solid state H.F.Nominal power (kW).welderI . Technical Description1. Features of new gen erati on H.F. solid state welder1.1 The solid state H.F. welder ado pts Germa ny IXYS company IXFN38N100Q238A/1000V high-power MOSFET and DSEI 261-12B 60A/1200V rap id recovery diode to comp ose series

6、 type inv ertible circuit.1.2The solid state H.F. welder adopts modularization design with more compactstructure which makes maintenance and high-po wer realizati on much easier.1.3It has p articular tech no logy of bridge-divided over-curre nt p rotecti on thatguara ntees equipment safety.1.4It com

7、bines international advaneed control method of same products, adoptsadva need tech no logies like fixed an gle p hase-lock ing con trol, upper freque ncy limit/lower freque ncy limit lock-lost p rotecti on and etc. With these tech no logies, the equipments run more stably, more efficiently, more acc

8、urate and effective p rotecti ons to the in ductor short-circuit and open-circuit malfu nction duri ng pipe weld ing p roducti on.1.5Lin e-i n end of solid state H.F. welder does not n eed ste p-up /ste p-dow n rectifiertran sformer, comp ared with vacuum tube welder and p arallel type welder; it ha

9、s sig nifica nt en ergy-sav ing effects (Un der same weldi ng con diti on, en ergy-sav ing 30% comp ared with vacuum tube welder).2. Model in structi ons for solid state H.F . welder3. Worki ng principle of solid state H.F. welder3.1Main circuit structure of solid state H.FSolid state H.F. welder ma

10、in circuit structure is as follows fig.1; it is a typ ical AC-DC-ACvariable freque ncy structure. Rectifier adopts3-p hasebridge style thyristor p hase-c on trol rectifier circuit, DC side adopts in ductor, cap acitor to compose LC filter which meet the work ing requireme nts of voltage type inv ert

11、er. The voltage type inv erterC-series, B-p arallelWeldi ngDesig ned out put freque ncy (MHz)Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal2.weldernear by resonance frequency of resonancetank circuit, and now the inv erter out putvoltage fun dame ntal wave

12、 from res onancetank circuit to inverter has the minimumimpedanee value, the maximum impedaneevalue to other high harmonics, thereforeadopts modularization parallel structure to extend power supply power, each inverter module is sin gle p hase MOSFET bridge style circuit conn ected with series res o

13、nance tank circuit by H.F. matching transformer. On one hand, the matching transformer realizes po wer comb in ati on and imp eda nee match ing; on the other hand it realizes electric isolation of load and power supply. To put effective and swift protection on over-current malfunction of voltage typ

14、e inverter, our company introduces special and stable over-current protection circuit which guarantees safe and stable running ofinv erter.Fig 1 Circuit structure of solid state H.F3.2Worki ng principle of solid state H.F . welderVoltage type res onance inv erter also called series connection type r

15、es onance inv erter is the most critical part of the whole solid state H.F. po wer supply; fig 2 shows the structure, out put voltage and curre nt wave of inv erter module. By con trolli ng connection and disc onnection alter natively of MOS 1&3, MOS 2&4, the series connection type inverterout put v

16、oltage u H is close to square-wave, due to the inv erter out put voltage freque ncy isload current i H is close to sine waveform.Matchi ng tran sformerABCOver-curre nt Voltage type p rotecti onin verterBaoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal3s roaro

17、utagezZVS),Series connection resonance inverter typical working state can be divided into threetyp es: sen sibility, resistive leakage, cap acitive. Fig 3 shows sep arately the three work ingFig 3 Series connection resonance in verter out put waveformsWhen series connection resonance inverter works

18、at small sensitivity status (fig 3a), inv erter s work ing frequey is higher tha n in here nt res onance freque ncy of res onancetank circuit a little bit, i.e. load current iH lag to load voltage u H a electric angle W . Nowcurrent- exchange of inverter has several features: 1) Part zero current (Z

19、CS), theoretically the wastage of the part s startup is zero; 2) Part s shutdow n is zero voltage, non -zero curre nt, but due to small curre nt whe n part s shutdown, plus zero voltage current-exchange (ZVS), so part shutdown wastage is small too; 3) circuit stray in ducta nee has small effect on i

20、n verter curre nt-excha nge; 4) curre nt-excha nge has no requireme nt on backward recovery features of in verse p arallel diode, the p arts suffer very small surge impact whe n curre nt-excha nging.When series connection res onance in verter works at cap acitive status (fig 3b), i nv erter worki ng

21、 freque ncy is lower tha n in here nt res onance freque ncy of res onance tank circuitFig 2 Voltage type resonance in verter circuit structure and out put waveformstatus inv erter out put voltage, curre nt and exp erime nt waveforms.(a) small sensitivity status (b) small capacitive status (c) resist

22、ive leakage statusBaoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal4a little bit, i.e. load current iH advanee to load voltage UH a electricangle W . Nowcurrent-exchange of inverter has several features: 1) Part s shutdownis zero voltage(ZVS), zero curre nt (

23、ZCS), theoretically the wastage of the parts shutdown is zero; 2)Part s startup is high voltage, large current, so part slartup wastageis very big; 3)circuit stray inductanee has strong effect on inverter current-exchange;4) backwardrecovery curre nt of in verse p arallel diode of MOS yield stro ng

24、voltage curre nt oscillatio n,the p arts suffer very strong surge impact whe n curre nt-excha ngin g, it threate ns powerpart safety running severely.When series connection res onance in verter works at resistive leakage status (fig 3c), itwork ing freque ncy equals in here nt res onance freque ncy

25、of res onance tank circuit, i.e.load current iH has the same phase position with load voltage UH. Theoretically theresistive leakage status is the best work ing status, but actually due to the effects ofdead zone p eriodand resista nee & cap acita neeabsor pti oncircuit,inv ertercurrent- exchange pa

26、rt s working status is not in good condition, also load fluctuationmakes inverter deviate to capacitive working status easily, it threatensstable andsafe running of inv erter.From the analysis above we know that the best working status of seriesconnectionresonance in verter is small sen sitivity sta

27、 ndard res onance status.Besides, compared with other company s parallel connection resonanceH.F. powersupply, our company s series connection resonance H.F. power supply parts not only hassmall switch wastage and high power supply efficiency, but also has much betterp rotect ion to various malf un

28、cti ons of res onance tank circuit.4. Tech ni cal p arameters of 500kW solid state H.F. welder Designed parametersNomi nal po wer: 500kWRated DC power: P d=600kWRated DC voltage: U dN=450VRated DC current: I dN=1330APower supply efficiency:n85%Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid Sta

29、te H.F. Welder Technical Prop osal5Baoding Sanyi Tianxing Electric Co., Ltd.500kW Solid State H.F. Welder Technical Prop osal6Output po wer: P out 500kWDesig ned freque ncy: f=150200kHzMOSFET i nverter: 120kW 5Tank circuit out put mode: no weld ing tran sformer out put, sec on dary res onance Power

30、distribution requirementsNomi nal po wer: 500kWRated DC power: P d=600kWLine- in power factor: COS 少 0.Power distribution cap acity: S 為70kVAPower supply voltage: 3-p hase 380V/50HzLin e-in curre nt: I=1090A2Line-in cable: each phase adopts two pieces of 240mm copper cable conn ected in p arallel, 3

31、-p hase 4-1 ine Water-water cooling systemWith the adop ti on of water-water heat excha ngerP ressure of inner circulatio n water: 0.150.25 MPa3Flow of inner circulati on water: 65.4m /hTemp erature of inner circulati on out water: 403Temp erature of inner circulati on back water:N5 32Heat excha nge

32、r area: 酒m3Flow of external circulation water: 65.4m /h (provided by user )Temp erature of exter nal circulati on inlet water:6mm grounding resista nee: 4Q.Height above sea level should be no more tha n should be reduced to be op erated.Ambient temperature: -5 C+40 CAir relative humidity: 85%.No sev

33、ere vibrati on, no con ductive dust, no various causticity gas and expl osi on gas.In stallati on gradie nt: 5nd in stall in the pl ace with good ven tilati on con diti on.2. Po wer n et requireme ntsPo wer net voltage should be si ne wave, harm onics distorti on: 5%.Imbalanee degree between 3-phase

34、 voltage:v 5%.Po wer net input voltage is line voltage AC 380V, continu ous fluctuati on range: 10%, power net frequency variation: 2% (i.e. between 49 51Hz).3. Water quality requireme nts for exter nal circulati on water p oolThe water quality for exter nal circulati on water pool will directly aff

35、ect the op erati on of water-water cooli ng system, and eve n the reliability of the equipment. So it is suggested to the user that adopts running water for outer po ol, and the associated requireme nts are as below:The water quality should be transparent, no turbidity, deposit and scale. The water pipe for water should be p reve nted from fouli ngThe cooling pool should be no impurity so as to prevent the pipeline of water-water cooli ng system from block ing which can in flue nee the heat excha nging effe