Transform seam welder to increase production and save electricity
Huaiyin City Institute of Science and Technology Information Yang Yanchang
The seam welder is the main equipment for the production of oil drums in Qingjiang Metal Container Factory. It has been using 150kVA continuous resistance lap welder for many years. At present, China has entered the stage of using pulse seam welding machine. Some countries have adopted frequency conversion (gongxian 2 pulse seam welding machine. Old-fashioned continuous seam welding machine, large power consumption, high temperature, main transformer often burned out, is the production line of the factory The key issue is that if the factory is wrapped around two existing seam welders, the pulse seam welder will be replaced, each of which will cost 2-4 million yuan, a total of 48,000 yuan, and is not available from the domestic market. Leaders and scientific and technological personnel to study together? Decided to tap the potential of equipment:. To carry out technological transformation, so that we can meet the production needs. According to the above situation, we have carried out the following transformation on the 150kVA seam welding machine.
1. Transforming the main transformer
The measured calculation of the original transformer shows that the åŒ/V is small and the wire diameter is small. For the above two points, change the original design 0.25 åŒ / volt to 0.27 åŒ / volt; change the wire cross-sectional area 63.4mm2 to 74.8mm2. In this way, the DC resistance is reduced to 26.8% of the original resistance value. After installation (after changing the three parts), the current on the primary side of the load drops from the original 260A to 80A. The original 180A (260--80 = 180) current is almost completely changed. For heat energy, the transformation not only limits the temperature rise, but also saves energy.
2. Reconstructing the length of the welding arm
The original welding arm is 1130mm long and is now changed to 940mm. Thus, on the one hand, the resistance of the arm length is reduced, and the static pressure of the solder joint is increased, which not only brings about the power saving effect, but also greatly reduces the cracking phenomenon in the seam welding process.
3. Thoroughly improve insulation conditions
The principle of the seam welder is low voltage and large current, so that the workpiece to be welded is welded in the molten state. Because the voltage is low, the current is large, and the insulation requirement is not high under normal circumstances. However, the actual measurement shows that the main cause of the main transformer heating is only the leakage of the low voltage part, especially the body column is non-conducting body, but it is warm during use. The rise is very high, which is caused entirely by the leakage current loop through the column. In the transformation, mica with high mechanical strength is used as the insulation layer. After long-term use, the column is heated. Like complete elimination.
4. The economic benefits after the transformation are as follows:
The original class output was 400, and the converted output was 700 (200 liter drums). The reason was that there was a sudden cooling in the past, and now there is no need to stop cooling, which will increase the equipment utilization by 75%. Each machine saves 421.6 kWh per shift, saving 10,750 kWh of electricity per month, saving a total of 12,000 kWh of electricity a year, equivalent to 16,770 yuan.
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