3. Horizontal Accumulator:

4. Forming Machine: 

5. Roller Stands with Carriage System for Front Horizontal Stands in

Forming and Sizing Sections (easy change): 
This system includes two sets of roller stands mounted on movable carriages (or

trolleys):

• One set for the Forming section

• One set for the Sizing section

These stands are installed on rails or wheeled carriages, allowing for smooth and

controlled movement of the roller assemblies.

Advantages:

1. Reduced roller changing time and increased production capacity:

With carriage-mounted roller stands, there’s no need for time-consuming manual disassembly.

The entire roller unit can be shifted easily, minimizing machine downtime and enhancing throughput.

2. Prevention of bearing damage and extended equipment lifespan:

In conventional setups, manually pulling out the roller frame can place excessive stress on bearings, leading to premature wear or failure.

The carriage system enables smooth and uniform movement, significantly reducing stress and potential damage to mechanical components.

3. Improved alignment and accuracy:

Carriage-mounted rollers can be positioned with high precision, ensuring better

alignment during tube forming and sizing processes.

Enhanced maintenance and safety:

Simplified access to the rollers facilitates maintenance and reduces the risk of worker injury

compared to manual frame handling.
1.1 Main Parameters:

• Rated Output Power: 300 kW

• Rated DC Voltage: 235 V

• Rated DC Current: 1500 A

• Overall Efficiency: η≈90%

• Output Frequency: 300–350 kHz

• Resonance Type: Compound Resonance

• Tank Circuit Output: No welding transformer output.

• Ripple Factor: < 0.5%

• Welding Method: Induction Welding

• Power Supply Capacity: 375 kVA

• Input Voltage: 3-phase, 380 V / 50 Hz, 4-wire system

• Rated Input Current: 569A

Cooling System (Soft Water Circulation – Air-Water Type):

• Operating Water Pressure: 0.32 MPa

• Water Flow Rate: 30 m³/h

• Cooling Capacity: 110 KW
2. System composition:

The solid state high frequency all-in-one welder consists of four main parts:

IGBT high frequency inverter with PWM voltage regulator,

High frequency transformer,

High-frequency rectifier using FRED fast recovery diode module,

E-bridge inverter output.

AC voltage regulation with PWM is integrated into a single control board. The PWM control

unit is embedded on the main board, with its main functions managed by a single-chip

microcomputer and PWM control system. Voltage adjustment and feedback control are

achieved through the dual closed loop PI regulator on the main board.

Alarm and protection control are based on a digital circuit as the control core, combined with

fast response hardware, ensuring sensitive and precise protection actions.

This welder uses a full-wave rectification and IGBT inverter regulation mode, eliminating the need for phase angle control used in older systems. As a result, it offers high power factor,energy saving performance, and reduces the cross sectional area required for input cables.
Solid state HF welder is designed for continuous working. Rectifier inverter integrated structure, compact size easy to install. The whole set of equipment achieves the function of equipment linkage control and diagnosing faults by PLC system. The working statue is observed by LCD display.
Inverter adopts E bridge structure. The main power parts are IRFP460 from IR Company

and DSEI60-06A fast recovery diode from IXYS Company in US, which are composing current inverter.

The output power of single layer power module is 50KW, the equipment are parallel connected by multilayer power modules. The rated work frequency is 400KHz. The same power module is interchangeable. This power module can work steadily in 600KHz,

therefore it can work in 400KHz easily. The technique of the equipment is well proven.

3. Performance and Efficiency Gains with IGBT Inverter Technology:
1. High Energy Efficiency:

IGBT modules offer low switching losses, enabling system efficiency greater than 90%.

2. Stable Output and Consistent Weld Quality:

Precise voltage and frequency regulation via PWM ensures steady operation and uniform weld seams.

3. High Power Factor and Reduced Energy Consumption:

The use of full wave rectification and elimination of phase-angle control significantly improves power factor and reduces electrical losses.

4. Compact System Design:

IGBT inverters eliminate the need for bulky phase-control components, resulting in a more compact and space-saving layout.

5. Reduced Input Cable Size:

Due to stable current draw and improved power factor, smaller input cables can be used, lowering installation costs.

6. Enhanced Reliability and Low Maintenance:

Solid-state construction with no moving parts increases operational life and minimizes maintenance requirements.

7. Advanced Digital Protection Compatibility:

Fully compatible with fast response digital protection systems, ensuring precise fault detection and improved operational safety.
4. Main Components List:

5. Scraper Frames:

Function:

Two sets of scraper frames are installed to remove the external weld bead formed

after the HF welding process. This operation enhances surface quality and prevents interference in subsequent processes like coating or sizing.
Design Features:

• Each frame is equipped with an adjusting pole for precise positioning.

• Includes a quick feed-in and feed-out mechanism, allowing fast and efficient changeovers during production shifts.

• Facilitates easy maintenance and adjustment based on pipe diameter and

• weld bead profile.