English
Created on 06.01
Medium Frequency Inverter Resistance Welding Power Controller & Transformer Series
Our medium frequency inverter resistance welding power system consists of IDW series welding power controller and supporting medium frequency welding transformer. As core power units for modern resistance welding machines, this integrated solution adopts advanced IGBT inversion technology and nano-amorphous transformer core. Compared with traditional line-frequency AC welding equipment, it features faster response, higher control precision, lower energy consumption and better grid compatibility. It is widely used for spot welding, projection welding, seam welding and automatic robot welding production lines.
1. Advantages: Medium Frequency VS Conventional Line-Frequency Welding Equipment
Comparison Item | Conventional Line-Frequency AC Welding Machine | Medium-Frequency Inverter DC Welding System |
Welding Performance | Adjust output current by thyristor firing angle; low power factor. Long adjustment cycle up to 20ms, slow response and poor control accuracy. | Three-phase AC-DC-IGBT inversion design. 1ms ultra-fast adjustment response, 20 times faster than traditional machines. Steady current output and outstanding control accuracy. |
Power Grid Adaptability | Single-phase 380V input, causing severe three-phase current imbalance. Low grid utilization rate, high reactive power and serious grid harmonic pollution. | Balanced three-phase 380V input with full-wave rectification. Power factor reaches above 90%, no grid pollution, supporting multi-machine parallel operation stably. |
Welding Current Control | AC current with regular zero-crossing blank heating. Dispersed welding heat, unstable welding quality and obvious welding spatter. Easily affected by grid voltage fluctuation. | Pure DC output without current zero-crossing. Centralized welding heat, less spatter, longer electrode service life. Almost no influence from secondary circuit inductance and grid fluctuation. |
Supporting Transformer | 50/60Hz low-frequency transformer, bulky volume, heavy weight, high power loss and low working efficiency. | 1kHz medium frequency transformer, compact structure, low loss, high efficiency, easy installation and layout inside welding machines. |
- Overall Product Superiority
- Besides above core strengths, our medium frequency welding power system supports diversified welding processes and covers full welding material compatibility. It can weld galvanized steel, coated steel, stainless steel, aluminum alloy and various dissimilar metals, meeting complex welding demands of modern manufacturing industry.
2. Core Features of Welding Power Controller
- Adjustable Working Frequency: 1kHz - 4kHz output frequency, millisecond-level high time precision
- Abundant Welding Programs: Built-in 32 groups of programmable welding specifications, expandable to 256 groups
- Three-Stage Welding Process: Complete preheating, welding and tempering process; customizable current ramp-up, ramp-down and welding cycle times
- Strong External Compatibility: 3 groups of programmable output ports, perfectly matched with PLC, welding robots and automatic production lines
- Industrial Communication Function: Support RS485 communication and BCD code control, realizing remote control and centralized automatic management
- High-precision Closed-loop Control: Real-time secondary current feedback system, current control accuracy up to 5‰
- Built-in Alarm Recording System: Automatically store historical fault records for quick troubleshooting and daily maintenance
3. Main Technical Parameters of IDW Series Welding Controller
Model | Max Output Current | Matching Transformer | Max Short-circuit Current | Air Switch Capacity | Current Setting Range |
DW400L | 400A | 90KVA | 20KA | 100A | 0-400A / 0-20KA |
IDW-600T | 600A | 120KVA | 30KA | 100A | 0-600A / 0-30KA |
IDW-800T | 900A | 180KVA | 40KA | 125A | 0-900A / 0-40KA |
IDW-1000T | 1100A | 200KVA | 50KA | 160A | 0-1000A / 0-50KA |
IDW-1200T | 1300A | 250KVA | 60KA | 160A | 0-1300A / 0-60KA |
IDW-1800T | 1800A | 350KVA | 72KA | 200A | 0-1800A / 0-72KA |
IDW-2400 | 2400A | 350*2KVA | 96KA | 400A | 0-2400A / 0-96KA |
- General Controller Technical Parameters
- Inverter Mode: Medium Frequency DC
- Input Voltage: 3-phase 380V, voltage fluctuation: +10% / -20%, 50/60Hz±1%
- Control Mode: Constant Current / Constant Conduction Angle
- Output Frequency: 1kHz / 4kHz optional
- Solenoid Valve Output: DC24V±10%, single channel current ≤0.15A
- Air Valve Configuration: 4 standard air valves; 10 air valves specially for seam welding
- Cooling Water Requirement: 6-12L/min, water pressure ≥0.15MPa, water temperature ≤40℃
- Working Environment: Working temperature: -5℃~50℃; Ambient humidity ≤80%; Max working altitude: 1km
- Insulation Class: Class F
- Dimension: Standard size, customized design available
4. Matching Medium Frequency Welding Transformer Parameters
- We provide complete supporting medium frequency welding transformers matched with all IDW controller models. Adopting nano-amorphous iron-based core material, the transformer features low core loss, high thermal stability and excellent DC welding output performance.
Model | Rated Power (kVA) | Duty Cycle | Primary Voltage (V) | Frequency | Rated Current (kA) | Max Current (kA) | Turns Ratio | Insulation Class | Secondary No-load Voltage (V) |
Y90 | 75 | 50% | 500 | 1K/4K | 15 | 23 | 55:1 | F | 9 |
Y120 | 120 | 50% | 500 | 1K/4K | 21 | 38 | 50:1 | F | 10 |
Y180 | 160 | 50% | 500 | 1K/4K | 30 | 43 | 50:1 | F | 10 |
Y250 | 250 | 50% | 500 | 1K | 42 | 55 | 40:1 | F | 12.5 |
Y350 | 300 | 50% | 500 | 1K | 55 | 65 | 40:1 | F | 12.5 |
5.7-inch Touch Screen Operation Panel
- Human-machine Interactive Interface: Equipped with industrial 7-inch touch screen, easy parameter setting and function selection
- Real-time Data Monitoring: Dynamically display welding current, capacitor voltage and other running data
- Three Core Operation Screens
- Working Status Screen: Auto startup interface after power on; official welding operation only available on this page
- Parameter Setting Screen: One-click configuration of all welding technological parameters
- Function Setting Screen: Support single/continuous welding, seam welding mode, current switching, water flow detection, electrode dressing and cyclic welding functions
6. Application Fields
- This integrated medium frequency welding power system is widely applied in automotive manufacturing, auto parts processing, sheet metal welding, hardware fastener projection welding, new energy industry, household appliance production and automated robot welding lines. It matches all kinds of medium frequency resistance welding machines perfectly.
Conclusion
- Our medium frequency inverter welding controller and matching transformer form a complete high-efficiency welding power solution. Featuring fast response, high control precision, energy saving and stable operation, it upgrades traditional low-frequency welding equipment comprehensively. Full standard models are in stock, customized service is available to meet your special welding demands. Welcome to contact us for quotation and technical support.
Contact
Leave your information and we will contact you.
WhatsApp