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Created on 05.20
IDW Series Medium Frequency Inverter Resistance Welding Controller | Complete Specifications
The IDW Series Medium Frequency Inverter Resistance Welding Controller is an advanced MFDC (Medium Frequency Direct Current) control system specially designed for industrial resistance welding equipment. Compared with traditional line-frequency AC welding controllers, our medium-frequency inverter controller features balanced three-phase input, higher power factor, precise millisecond-level control, stable DC output and lower energy consumption. Widely used in spot welding, projection welding, nut welding, seam welding and automated welding production lines.
1. Advantages: Medium Frequency Inverter VS Traditional Line Frequency Welding Machine
Comparison Category | Conventional Line-Frequency AC Welding Machine | Medium-Frequency Inverter DC Controller |
Performance | Adjust the secondary voltage through thyristor firing angle; low power factor. Long adjustment cycle (20ms). | IGBT inversion technology, 1kHz working frequency. Ultra-fast 1ms response time, 20 times faster than traditional machines. Higher control accuracy and stable output. |
Power Grid | Single-phase 380V input, severe three-phase imbalance, high grid pollution and low grid utilization. | Three-phase 380V balanced input. Power factor over 90%, low grid fluctuation and energy saving. |
Power Control | AC current with zero-crossing blank heating. Poor heat concentration, unstable welding quality and obvious current fluctuation. | Pure DC output without zero-crossing. Concentrated welding heat, less spatter, longer electrode life, not affected by grid voltage fluctuation. |
Transformer | 50/60Hz low-frequency transformer, bulky size, heavy weight and high loss. | 1kHz medium frequency transformer, compact structure, low loss, high efficiency and easy installation. |
2. Main Controller Features
- Adjustable Working Frequency: 1kHz ~ 4kHz, millisecond-level time precision.
- Rich Welding Programs: 32 groups of welding specifications (expandable to 256 groups).
- Three-stage Heating Process: Preheating → Welding → Tempering. Support customizable ramp-up, ramp-down and cyclic welding times.
- Programmable I/O Ports: 3-stage programmable output, compatible with PLC, robots and automatic production lines.
- Industrial Communication: RS485 communication and BCD code control, supporting remote monitoring and automated management.
- Closed-loop Current Feedback: Real-time secondary current feedback, current control accuracy up to 5‰.
- Alarm Recording System: Automatically record fault alarm data for equipment maintenance and troubleshooting.
3. Product Parameter Table
Model | Max Output Current | Matching Transformer | Max Short-circuit Current | Air Switch Capacity |
DW400L | 400A | 90KVA | 20KA | 100A |
IDW-600T | 600A | 120KVA | 30KA | 100A |
IDW-800T | 900A | 180KVA | 40KA | 125A |
IDW-1000T | 1100A | 200KVA | 50KA | 160A |
IDW-1200T | 1300A | 250KVA | 60KA | 160A |
IDW-1800T | 1800A | 350KVA | 72KA | 200A |
IDW-2400 | 2400A | 350*2KVA | 96KA | 400A |
General Technical Parameters
- Inverter Mode: Medium Frequency DC
- Input Voltage: Three-phase 380V, fluctuation +10%/-20%, 50/60Hz
- Control Mode: Constant Current / Constant Conduction Angle
- Inverter Frequency: 1KHz / 4KHz optional
- Solenoid Valve Output: DC24V±10%, ≤0.15A per channel
- Communication Mode: RS485
- Cooling Water Requirement: 6~12L/min, ≥0.15Mpa, water temperature ≤40℃
- Working Temperature: -5℃ ~ 50℃ (water cooling)
- Insulation Class: Class F
- Air Valve Configuration: 4 standard air valves; 10 air valves for seam welding type
4. Welding Time & Current Adjustable Parameters
The controller supports fully customizable multi-stage welding time and multi-group current settings to meet complex welding craft requirements.
- Time Parameters: Pre-pressure, Pressure, Preheat, Welding, Cooling, Tempering, Hold and Idle time (0~9999ms adjustable).
- Ramp Time: Ramp-up / Ramp-down time: 0~99ms.
- Current Control Mode: Primary Constant Current & Secondary Constant Current. Three groups of independent current settings for multi-pulse welding.
5. Touch Screen Panel & Operation System
- 7-inch Industrial Touch Screen: Intuitive human-machine interface, simple and clear operation.
- Real-time Monitoring: Display welding current, capacitor voltage and running data dynamically.
- Working Status Screen: Default startup page for formal welding production.
- Parameter Setting Screen: One-click configuration of all welding technological parameters.
- Function Setting Screen: Single/continuous welding, seam welding mode, water flow detection, electrode dressing, cycle welding and other functions.
6. Application Scope
IDW medium frequency welding controllers are widely applied in automotive manufacturing, sheet metal processing, hardware fasteners, galvanized steel, stainless steel, aluminum alloy and dissimilar metal welding. Compatible with manual spot welders, automatic welding machines, robot welding systems and nut projection welding equipment.
7. Conclusion
With three-phase balanced power input, ultra-high current control accuracy, durable water cooling system, and industrial touch screen operation, the IDW series medium frequency inverter welding controllers are the ideal replacement for traditional AC welding control systems. Stable performance, low energy consumption, and strong compatibility make them the core control equipment for modern intelligent resistance welding production lines. If you require customized parameters or technical support, please feel free to contact us.
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