Technical Proposal for 700kW solid state HF Welder.docx
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Technical Proposal for 700kW solid state HF Welder.docx
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TechnicalProposalfor700kWsolidstateHFWelder
TechnicalProposal
of
700kWSolidStateHFWelder
BaodingSifangSanyiElectricCo.,Ltd.
2015.4
CATALOGUE
Ⅰ.TechnicalDescription1
1.FeaturesofnewgenerationH.F.solidstatewelder1
2.ModelinstructionsforsolidstateH.F.welder1
3.WorkingprincipleofsolidstateH.F.welder1
3.1MaincircuitstructureofsolidstateH.F.welder1
3.2WorkingprincipleofsolidstateH.F.welder2
4.Technicalparametersof500kWsolidstateH.F.welder4
5.Coretechnicalinstructionsofcontrolandprotection5
6.MainpartslistforsolidstateH.F.welder6
Ⅱ.CompositionandBriefIntroductionforSolidStateH.F.Welder7
1.Equipmentcomposition7
2.BriefintroductionforsolidstateH.F.welder7
Ⅲ.SupplyList9
Ⅳ.RequirementsforEquipmentOperation9
1.Environmentrequirements9
2.Powernetrequirements9
3.Waterqualityrequirementsforexternalcirculationwaterpool9
Ⅴ.SupplyScope10
1.Supplyscopeforseller10
2.Supplyscopeforbuyer10
Ⅰ.TechnicalDescription
1.FeaturesofnewgenerationH.F.solidstatewelder
1.1ThesolidstateH.F.welderadoptsGermanyIXYScompanyIXFN38N100Q238A/1000Vhigh-powerMOSFETandDSEI2×61-12B60A/1200Vrapidrecoverydiodetocomposeseriestypeinvertiblecircuit.
1.2ThesolidstateH.F.welderadoptsmodularizationdesignwithmorecompactstructurewhichmakesmaintenanceandhigh-powerrealizationmucheasier.
1.3Ithasparticulartechnologyofbridge-dividedover-currentprotectionthatguaranteesequipmentsafety.
1.4Itcombinesinternationaladvancedcontrolmethodofsameproducts,adoptsadvancedtechnologieslikefixedanglephase-lockingcontrol,upperfrequencylimit/lowerfrequencylimitlock-lostprotectionandetc.Withthesetechnologies,theequipmentsrunmorestably,moreefficiently,moreaccurateandeffectiveprotectionstotheinductorshort-circuitandopen-circuitmalfunctionduringpipeweldingproduction.
1.5Line-inendofsolidstateH.F.welderdoesnotneedstep-up/step-downrectifiertransformer,comparedwithvacuumtubewelderandparalleltypewelder;ithassignificantenergy-savingeffects(Undersameweldingcondition,energy-saving≥30%comparedwithvacuumtubewelder).
2.ModelinstructionsforsolidstateH.F.welder
3.WorkingprincipleofsolidstateH.F.welder
3.1MaincircuitstructureofsolidstateH.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
3.2WorkingprincipleofsolidstateH.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.
Besides,comparedwithothercompany’sparallelconnectionresonanceH.F.powersupply,ourcompany’sseriesconnectionresonanceH.F.powersupplypartsnotonlyhassmallswitchwastageandhighpowersupplyefficiency,butalsohasmuchbetterprotectiontovariousmalfunctionsofresonancetankcircuit.
4.Technicalparametersof700kWsolidstateH.F.welder
①Designedparameters
●Nominalpower:
700kW
●RatedDCpower:
Pd=840kW
●RatedDCvoltage:
UdN=450V
●RatedDCcurrent:
IdN=1870A
●Powersupplyefficiency:
η≥85%
●Outputpower:
Pout>700kW
●Designedfrequency:
f=150~200kHz
●MOSFETinverter:
120kW×7
●Tankcircuitoutputmode:
noweldingtransformeroutput,secondaryresonance
②Powerdistributionrequirements
●Nominalpower:
700kW
●RatedDCpower:
Pd=840kW
●Line-inpowerfactor:
COSφ≥0.9
●Powerdistributioncapacity:
S≥930kVA
●Powersupplyvoltage:
3-phase380V/50Hz
●Line-incurrent:
I=1520A
●Line-incable:
eachphaseadoptsthreepiecesof240mm2coppercableconnectedinparallel,3-phase4-line
③Water-watercoolingsystem
●Withtheadoptionofwater-waterheatexchanger
●Pressureofinnercirculationwater:
0.15~0.25MPa
◆Flowofinnercirculationwater:
100m3/h
◆Temperatureofinnercirculationoutwater:
≤40℃
◆Temperatureofinnercirculationbackwater:
≤45℃
●Heatexchangerarea:
≥25m2
●Flowofexternalcirculationwater:
100m3/h(providedbyuser)
◆Temperatureofexternalcirculationinletwater:
≤35℃
◆Pressureofinletwater:
0.20~0.3MPa(approximately2.0~3kg/cm2)
5.Coretechnicalinstructionsofcontrolandprotection
5.1SolidstateH.F.welderadoptsthemostadvancedfixed-angelphase-lockingcontroltechnique,inverterworkingstatusdonotchangeasloadtankcircuitchange,whichkeeptheworkatthebestsmallsensitivityresonancestatusallthetime,welderworksstablywithhighefficiency.
5.2SolidstateH.F.welderhasadvancedfunctionslikehigh/lowlock-lostprotection,frequencyupperlimit/lowerlimitprotection,invertover-current,tankcircuitover-voltageandetc.Alsomoreaccurateandefficientonopen-circuit,short-circuit,arcingofinductormalfunction,itguaranteeswelderstablerunning.
5.3Besidesregularprotections,eachinverterbridgeadoptsmultipleprotections,suchasDCsideover-current,ACsideover-current,ACsideover-voltageandetc.Itrealizesprotectionredundancy,guaranteesinvertersaferunning.
5.4Rectifiersidecontrolcircuitadoptssinglechiptechnologywhichsolvesautomaticphase-recognizesuccessfully,i.e.norequirementson3-phasepowersupplyinputline;thyristortriggercircuitadoptsalldigitalequalintervaltriggering,itreducesnon-characteristicsharmonicsfurthestandpowernetpollution.
5.5Rectifiercontrolcircuithas
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