High Efficiency Switch Welder

Power factor：0.95
Rated output power：60KW-600KW
Input Voltage：380V/50Hz 6% linear

Product description

The high-efficiency switch welder (all-in-one machine) is designed for straight seam induction (contact) welding of steel tubes. It mainly uses IRFP460 (MOSFET) and DSEI60-06A (fast recovery diode), rectifier diodes, and modular Power component consisting of high-power IGBT and other power devices. The high-power capacitor bank C and the inductance coil L form the current-mode parallel boost resonant circuit. This kind of circuit adapts to the high-frequency welded pipe with low load impedance and does not require the output transformer. This not only improves the efficiency but also increases the reliability of the whole machine.

The switch welder has such distinct features as high efficiency, less area covered, easy installation, low installation cost, high welder quality ect.

Dispay and alarm — the output current and voltage of the DC power unit; armature voltage and current, excitation voltage and current of the DC speed adjust unit.

Less installation cost

For example 100kw solid state welder, the traditional welder installation cost is around USD800(purchasing cable, nozzles, cable bridge and brackets), moreover, welder room or elevated platform is necessary, all the cost will be about USD800-1600.

Welding Quality

Benefitted from PWM precise control voltage and three level of filtering, the voltage output is stable, ripple coefficient is 50% lower than solid state welder. The welding quality is obviously better than traditional solid state welder.

Small harmonic interference, no pollution to the power grid

Three-phase AC power supply coverts the alternating current to the direct current through the full-bridge rectifier circuit. The line is equipped with a number of well-matched filter networks, leading to a very few harmonic components during operation of the high-efficiency switch welder (all-in-one machine). The power factor may reach 0.96 or more.

High Efficiency

Comparing to traditional solid state welder, save power for 15%-25%.

Less Area Covered

Saving 60% area than traditional solid state welder.

Easy installation

Comparing to the 5-7 days for traditional solid state welder installation, high efficiency switch welder installation is 1 day.

Environmental requirements

· Indoor installation with good grounding condition. Grounding wire color should be obviously different from control wires. Sectional area of grounding wire :> 120mm², grounding resistance: ≤4Ω.

· Height above sea level should be no more than 1000m, otherwise rated value should be reduced to be operated.

· Ambient temperature: -10℃~+45℃

· Air relative humidity: ≤85%.

· No severe vibration, no conductive dust, no various causticity gas and explosion gas.

· Installation gradient: ≤5°.

· Install in the place with good ventilation condition.

Advantage comparison

	high efficiency switch welder	solid state welder (Europe)	solid state welder (America)	Solid state welder (in Series)	solid state welder (in Parallel)
Rectifier transformer	No	No	Yes	No	Yes
Rectifier components	Diode	Diode	SCR	SCR	SCR
Inverter bridge output	Direct output	Transformer output	Direct output	Transformer output	Direct output
All in one design	Yes	No	No	No	No
Installation cost	Low	High	High	High	High
Energy consumption	Low	Low	Relatively high	High	High
Ripple	Low	Low	High	High	High
Power factor	High	High	Low	Low	Low

Ripple Comparison

	Initial 20V	120V	180V	230V
High efficiency switch welder
Solid state welder

Power factor comparison

	20V	80V	120V	150V	180V	200V	235V
High efficiency switch welder	0.65	0.9	0.94	0.95	0.96	0.96	0.96
Solid state welder	0.19	0.33	0.46	0.55	0.68	0.74	0.85