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Integrated intelligent welder

Short Description:

High-output solid-state welders More output: Continuous electronic load matching secures full power output across a wide range of tube sizes. More uptime: Short-circuit-proof, safe and reliable operation. Unrivalled efficiency: Diode rectifier with a constant power factor of 0.95 at all power levels, and an efficiency factor of 85-87%. Eco and energy friendly: High efficiency saves energy and reduces cooling water consumption. Easy to operate: An easy-to-use control panel with a mini...


Product Detail

Product Tags

High-output solid-state welders

  • More output: Continuous electronic load matching secures full power output across a wide range of tube sizes.
  • More uptime: Short-circuit-proof, safe and reliable operation.
  • Unrivalled efficiency: Diode rectifier with a constant power factor of 0.95 at all power levels, and an efficiency factor of 85-87%.
  • Eco and energy friendly: High efficiency saves energy and reduces cooling water consumption.
  • Easy to operate: An easy-to-use control panel with a minimum of manual settings makes the Weldac extremely easy to operate.
  • Wide range of power sizes: From 50 kW up to 2200 kW. A frequency range of 60-500 kHz.
  • Modern modular design: The small, compact footprint saves valuable floor-space and simplifies in-line integration. Up to 1100 kW available in a one-cabinet solution.
  • Complete system: Consisting of a diode rectifier, ­inverter modules, output section, busbar and operator control system.
  • Unmatched warranty: Five-year warranty on Weldac inverter modules and driver cards.
  • Full range of consumables:  Coils, ferrite, impeders and tube scarfing equipment.

Baoding Tongze Electrical Technology Co., Ltd. was founded in 2016, headquartered in Baoding City, Hebei Province. It is a large non-regional company integrating scientific research, manufacturing, trade and sales. Its registered capital is 26 million yuan. It has many agent companies under its jurisdiction. The company relies on the strong technical research and development of North China Electric Power University, Yanshan University and Baoding Electric Power Vocational and Technical College in the field of power electronics. Strong and rich management experience, the company’s products are in the forefront of the industry in terms of design concepts, technological research and development, as well as production technology, and are in the leading position in China.            Our company’s efficient and standardized enterprise operation and management mechanism has become a bridge for you to choose industries full of opportunities and challenges, which is our most valuable wealth and fundamental guarantee for the success of our cause. Today you step into the threshold of our company, tomorrow will be the bridge of your dream.            The company mainly produces and operates switchgear, power quality control equipment, solid state high frequency power supply and intelligent automation production line control system for 0.4kV/10kV AC transmission and distribution under high and low voltage. The company has more than 30 advanced production and testing equipment, more than 50 supplier cooperation units, more than 200 customers and 30 domestic and foreign distribution outlets. The marketing network covers the whole country and is exported to Europe, South America, the Middle East, Asia, Africa and other countries and regions.            Implementing the development concept of “innovation, coordination, green, openness and sharing”, closely around the construction of “one belt and one road”, we will uphold the tenet of “creating value and sharing success”, and strive to build world-class competitive equipment and excellent service providers of world-class technology and equipment, and drive global economic development with green power.

Enterprise purpose

Manufacture advanced equipment wholeheartedly          

 Serve high-quality customers wholeheartedly

Enterprise qualification

Performance characteristics of equipment

High efficiency and energy saving:        

   1. Adopting rectifier and inverter integrated cabinet design, it occupies small area and is easy to install.          

   2. The ripple coefficient is less than 0.5% by using three-phase full-controlled rectifier + IGBT inversion power regulation technology. High-frequency transformer is used instead of step-down transformer to reduce copper loss and hysteresis loss, and the inversion efficiency is high. With no cabinet connection and line loss removed, the energy saving of the whole machine is 15% higher than that of the previous generation products (universal type) (static test comparison).           

Multipurpose function:           

1. Low ripple coefficient satisfies the constant power output. It can be used for welding high-end automotive tubes, aluminum collector tubes, copper tubes and various stainless steel tubes.          

  2. The speed-power closed-loop control function can be optionally installed.        

Precision and stability performance:           

1. Adopt the unique soft-start control technology of main circuit.         

 2. Using precise high frequency inverted pulse PWM control technology        

 3. Autonomous current sharing control technology          

 4. Promoting and optimizing product process structure         

Interactive Intelligence:          

 1. Supporting cloud data services, real-time viewing of device operation through mobile APP.        

 2. Function expansion services can be provided according to user’s requirements.

quipment Configuration and Field Installation

Full Set of Configuration: The whole set of equipment of the new integrated welding machine includes three parts: welding machine, intelligent operation table and cooling system.            On-site installation: only three power lines are needed for on-site installation, and fast joints for inlet and outlet waterways are used. Aviation plugs are used for connection between welding machine and intelligent operation desk.

Selection of New Integrated Solid State High Frequency Welding Machine

Indicators/models TZGGP60-0.5 TZGGP100-0.4 TZGGP150-0.5 TZGGP200-0.4 TZGGP250-0.5 TZGGP300-0.5 TZGGP350-0.5 TZGGP400-0.5
output power 60KW 100KW 150KW 200KW 250KW      
DC voltage 250V 250V 250V 250V 250V      
Direct current 300A 500A 750A 1000A 1250A      
output frequency 550-630KHZ 350-420KHZ 350-420KHZ 350-420KHZ 350-400KHZ      
efficiency >90% >90% >90% >90% >90%      
Ripple coefficient 0.5% 0.5% 0.5% 0.5% 0.5%      
Module quantity 50kw*2 50kw*2 50kw*3 50kw*4 50kw*5      
Distribution capacity 78kva 130kva 200kva 250kva 320kva      
power factor >0.93
Power supply voltage According to customer’s on-site requirements
Maximum incoming current 111A 191A 287A 379A 485A      
Input Cable (Single Phase) 70mm² 95mm² 140mm² 190mm² 240mm²      
Working water pressure 0.25MPa 0.25MPa 0.25MPa 0.25MPa 0.25MPa      
Working water flow >17m³/H >17m³/H            
Cooling capacity >21500Kcal/H        
distilled water  
No rust, no pollution pipeline Non-ionic and mineral
Cooler (wind-water/water-water) 1200*800*1480mm 1300*1000*1480mm 1600*1550*1480mm 1700*1600*1480mm

Integrated anti-static metal enclosed cabinet design.

IGBT module unit adopts IP20 enclosed box structure, easy to maintain and install.

The combined water-cooled radiator adopts advanced friction stir welding technology. The unit reflux water channel design improves the radiation efficiency of the water-cooled radiator by 20%.

Welded Pipe Knowledge – Several Factors Affecting Welding Speed:

1. The geometric dimensions of the inductor, such as the diameter, width and turns of the inductor.

2. Distance from the front of the inductor to the center line of the extrusion roll

3. The length and position of the impedance (magnetic rod).

4. Opening angle of steel tube

The role of impedance in steel pipe welding:

In the actual pipe seam welding process, the impedance reduces the high-frequency current around the tube blank circumference. Correspondingly, the high frequency current of the weld edge is increased, which significantly improves the heating efficiency. Usually, the cross-sectional area of the magnetic conducting rod should account for 70% to 75% of the inner diameter of the billet. If the cross-sectional area is less than 70%, the welding efficiency will decrease obviously. Impedance devices (magnetic conductors) for high frequency welded pipes should have high initial permeability, as high Curie temperature as possible and low loss. In use, it should be noted that the cooling of the impedance (magnetic conductor) should be sufficient to prevent the impedance (magnetic conductor) from being crushed or failing when the temperature exceeds Curie point. The length and position of the impedance will affect the welding efficiency.

Contrast of Integral Welding Machine with Traditional Separate Welding Machine

Contrastive items Solid State Welder Solid State Welder New Integrated Solid State Welder
Protection speed commonly commonly fast
Remote monitoring nothing nothing Matching
Control Board Consistency Field test ield test No field testing is required
Safeguard Open circuit protection is difficult and short circuit protection is easy. Open circuit protection is easy and short circuit protection is difficult. Both are easy to achieve.
Power regulation mode Phase-shifting trigger Phase-shifting trigger or pulse shielding after the first 0-25% thyristor voltage regulation regulates the inverted impedance current (complex) Inverter PWM Control
Load matching Inductance adjustment Transformer tap, inductance, pulse shielding regulation Electronic regulation
Inverter output efficiency high General (perceptual) high
Output ripple coefficient 1% 1% 0.5%
power factor Depending on the output power Depending on the output power, when the rated power is above 25%, the power factor is 0.92. Full range 0.93
Design of Power Unit PCB design of open power module Tin Plating Process for Open Embedded Copper Tubes Closed IP20 Box Structure
Electrical isolation mode Step-down transformer Matched transformer  High frequency transformer
Controlled device (50HZ)SCR (50HZ)SCR IGBT (high frequency)
Installation mode It covers a large area, takes a lot of time and has many cabinet connections. It covers a large area, takes a lot of time and has many cabinet connections. Small area, fast installation, no cabinet connection
Debugging and maintenance High requirement for debugging and maintenance skills High requirement for debugging and maintenance skills Low Requirements for Debugging and Maintenance Skills
Maintainability good good excellent
Manufacturing cost Slightly lower high high
Operation and maintenance cost Slightly lower high low

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