Development of frequency conversion automatic steel barrel seam welding machine

Development of frequency conversion automatic steel barrel seam welding machine

Text / Mubo

The domestic 200-liter steel drum manufacturing industry has been developed for more than 100 years. The seam welding technology of steel drums is a key technical point affecting the quality of steel drums. For a long time, manual welding or semi-automatic welding machines have been used in seam welding of steel drums. The method is slow, the output is low, the scrap rate is high, and the manufacturing cost of the steel drum is high, which has been plagued by the majority of the barrel manufacturers. There are also several large-scale barrel mills in China that use foreign automatic welding machines. However, foreign automatic welding machines are expensive, spare parts are purchased for a long time, and replacement is cumbersome. Therefore, this equipment has become a bottleneck restricting the rapid development of the barrel industry.

To this end, Yingkou North Baking Equipment Technology Co., Ltd. independently developed a variable frequency (three-phase inverter) high-speed energy-saving automatic steel barrel seam welding production line, which is set after automatic feeding, coiling, spot welding, seam welding and welding. The automatic steel barrel welding production line that is transported into one body has the characteristics of saving labor, fast welding speed, good welding quality, smooth and smooth weld seam after seam welding, and less cracking. Not only has it filled the domestic gap, but its technology has reached the international leading level.

China's first frequency conversion automatic seam welder ribbon cutting

First, the introduction of frequency conversion automatic steel barrel seam welding machine

The HJ10 frequency conversion automatic steel barrel seam welding production line developed by Yingkou North Baking Equipment Technology Co., Ltd. is a fully automatic control electromechanical integration special welding machine production line. The welding machine adopts the principle of AC variable frequency resistance welding, that is, three-phase inverter welding control technology, with high automation, stable performance and reliable welding quality. The welder fully considers the characteristics of the steel drum plate, the use conditions of the power grid and other factors. Strong adaptability to sheet size, three-phase AC power input, power balance, high power factor; short welding time for the same welding workpiece, power saving, increased welding stability area, increased electrode life; less splash; Fast response control improves the quality of the solder joints. Reduce reactive losses. The steel plate is fully automated from the processes of feeding, dividing, grabbing and transporting. High transportation efficiency, accurate positioning and easy adjustment. Advanced technology and reasonable structure. The action is stable and reliable; the double sheet recognition of the steel plate is automatically monitored by the machine to enable the equipment to operate safely; the operation is smooth and noiseless, the operation is simple, and the maintenance is convenient.

All the equipment of the automatic steel barrel seam welder adopts heavy-duty structure design, which meets the production requirements of pre-cut steel plate feeding and longitudinal lap seam welding after rounding.

The welding machine integrates the functions of automatic feeding, coiling, welding, flat welding, unloading, etc. It adopts welding frequency conversion compensation electronic control system and PLC control system, configures color touch screen, realizes man-machine dialogue, and carries out the whole process of processing. Monitoring, simple adjustment and easy operation.

The production line will replace the original manual or semi-automatic welder in China. The original method is slow, the output is low, the scrap rate is high, and the manufacturing cost of the steel drum is very high, which has been plagued by the majority of the barrel manufacturers. The production line has the characteristics of high speed, good welding quality, low scrap rate, simple operation and maintenance, smooth weld seam and no pitting. It adapts to the needs of domestic and foreign markets, and its product technology has reached the international leading level, filling the domestic gap. The products of the project are adapted to the needs of domestic and international market development. The products have high added value, high performance, advanced production technology and high production efficiency. They are veritable equipment manufacturing products with high added value.

Main Specifications

project

unit

Technical indicators

1

Welding speed

Only / minute

10

2

Welding thickness

Mm

0.8 to 1.2 mm

3

Edge amount

Mm

3

4

Rejection rate

%

0.1

The production line has a patent and has completely independent intellectual property rights. The production line is mainly sold to the United States, Japan, Singapore, Iran and other countries. The main domestic customers include Shanghai Refining Metal Products Co., Ltd., Xin'an Packaging Company, Baiyin Yintong Company, Yantai Jindi Company, etc., which have huge market potential and broad development prospects.

Automatic seam welding machine host

Second, technical innovation points

1. Technical characteristics

HJ10 type frequency conversion automatic steel barrel seam welding production line is a fully automatic control electromechanical integration special production line. The principle of AC variable frequency resistance welding is called three-phase inverter welding control technology, with high degree of automation, stable performance and reliable welding quality. The production line fully considers the characteristics of the steel drum plate, the use conditions of the power grid and other factors, has strong adaptability to the plate size, high welding power factor, energy saving, and is the preferred equipment for steel barrel welding.

All the equipment of the automatic steel barrel seam welder adopts heavy-duty structure design, which meets the production requirements of pre-cut steel plate feeding and longitudinal lap seam welding after rounding. The welding machine integrates the functions of automatic feeding, coiling, welding, flat welding, unloading, etc. It adopts welding frequency conversion compensation electronic control system and PLC control system, configures color touch screen, realizes man-machine dialogue, and carries out the whole process of processing. Monitoring, simple adjustment and easy operation.

2, the main technical parameters

◆Board: cold rolled plate σb<450Mpa

◆Steel barrel size before welding: board width (barrel length / height) ± 0.5mm

◆ board length (barrel diameter) ± 0.5mm

◆ diagonal ≤ 1.0

â—†Sheet thickness: 0.8~1.2mm

◆Welding length: 500～1100mm

◆ barrel diameter: φ450 ~ φ600mm

◆ Welding overlap: 2.5±0.5mm

â—† Production speed: 10 / min

â—†Power supply: three-phase 380V, 50HZ /60HZ, power supply fluctuation +10%~20%

â—†Transformer: Single-phase AC transformer, rated capacity 250KVA,

â—† Air supply: pressure 0.6Mpa, compressed air.

◆Water supply: clean water, flow rate 6.3m3/h, pressure not higher than 0.1MPa, maximum inlet temperature 30°C.

3. Control principle

â—†Adopting variable frequency resistance welding (three-phase inverter) control

â—†AC variable frequency resistance welding (three-phase inverter welding) control working principle

â—†Three-phase AC 50/60HZ power input, rectified and filtered to become smooth DC, with IGBT/K1 as switching device to generate alternating voltage output, by adjusting the high-frequency (5KHZ) working IGBT/K2 open pulse width Set welding current output

4, the advantages of the control principle (that is, the advantages of AC frequency conversion control than power frequency control)

â—†Three-phase AC power input, power balance.

◆ High power factor, COS¢ reaches 0.9.

â—† Power consumption is reduced by approximately 60%.

â—† For the same welding workpiece, the welding time is shortened, saving time and electricity; the welding stability zone is enlarged.

â—†High quality welding quality, high welding frequency, small heating area and high permeability.

â—†The electrode life is greatly improved (up nearly 10 times higher than the ordinary power frequency).

â—†The welding control adjustment is simplified. A standard AC transformer can be connected. AC variable frequency welding (three-phase inverter welding) has intermediate frequency welding performance, without the use of secondary rectifiers, the reliability of the welding machine is improved. The unit consists of automatic feeding system, rounding machine system, servo pushing system, sizing system, welding wheel system, conveying system, cooling system, pneumatic control system and electrical control system.

5, the process

Coiling → Unwinding → Leveling → Shearing → Reeling → Spot Welding → Seam Welding → Flattening Welds → Unloading of Barrels → Pulling Edges and Reinforcing Bars → Ripple W Bars → Crimping → Leak Detection → Degreasing → Washing → Phosphating→washing→cleaning and drying→cooling→outside painting→outside spray drying→intake

Start → automatic feeding → roll round → servo push → sizing device → welding → flattening weld → unloading from the barrel → turning down the process

6, the main innovation, advanced

1) Adopt AC variable frequency resistance welding welding principle, namely three-phase inverter welding control technology, with advanced production technology, high degree of automation, stable performance and reliable welding quality.

2) The design of the steel drum plate characteristics, the use conditions of the power grid and other factors, the plate size adaptability, welding power factor is high, energy saving.

3) Adopt welding frequency compensation electronic control system and PLC control system, configure color touch screen, realize man-machine dialogue, monitor the whole process of processing, simple adjustment and convenient operation.

Automatic seam welding machine feeding system

Third, the performance indicators are compared with similar domestic and foreign

1) Domestic: manual or semi-automatic welding

The welding speed is slow, the output is low, the welding quality is poor, the weld is not enough, the undulation is uneven, there is a certain cracking phenomenon, the labor is wasted, the scrap rate is high, and the steel drum manufacturing cost is high.

2) Our company: HJ10 high-speed energy-saving frequency conversion automatic steel barrel seam welding production line

Fast welding speed, high output, good welding quality, smooth and smooth weld seam, no cracking, labor saving, simple operation and maintenance, low scrap rate and low cost. It can completely replace imported automatic welding machine, and the technology has reached the international leading level. The performance is far superior to similar products at home and abroad. The market share has reached more than 50%, and the product market has broad prospects.

Shanghai production site measured data can prove that our welder is superior to foreign welders

US Calando welder: incoming line current 170 ~ 180A; welder power: 170A × 380V = 64.6KW

Our company's welding machine: three-phase incoming current <90A; welding machine power: 90A × 1.732 × 380V = 59KW

AC variable frequency welding (three-phase inverter welding) has intermediate frequency welding performance, without the use of secondary rectifiers, the reliability of the welding machine is improved.

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