200kW HF Welder for ERW Tube Mill

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200kW HF Welder for ERW Tube Mill

What is a 200kW High-Frequency Welder?

A 200kW HF Welder is a powerful industrial welding system used to join the longitudinal seam of steel pipes by applying high-frequency electric current. It is commonly used in ERW pipe production lines for welding round, square, or rectangular steel tubes.

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What is a 200kW High-Frequency Welder?

200kW: The welder delivers 200 kilowatts of electrical power — suitable for larger diameter and thicker-wall pipes (typically up to 219mm or more in diameter).
High-Frequency: Uses AC current at 150–400 kHz, which rapidly heats the pipe edges by electrical resistance.
Solid-State Type (usually): Uses advanced semiconductors (IGBT or MOSFET) for higher efficiency and reliability.

⚙️ How Does a 200kW HF Welder Work?

The steel strip is formed into a tube using a forming mill.
As the two edges come together, a high-frequency current is introduced (via induction coil or contact tips).
The electrical resistance at the joint generates heat rapidly.
No external filler or flame is used — the edges are forged together by squeeze rollers.
This creates a clean, high-strength weld with minimal heat-affected zone (HAZ).

🧠 How to Choose a 200kW HF Welder

Factor	Considerations
Pipe Size	Pipe diameter and wall thickness
Material Type	Mild steel, carbon steel, stainless steel, or galvanized steel
Welding Speed	Production line speed — higher power supports faster welding
Induction vs. Contact	Induction is non-contact (cleaner); contact welding is more efficient for thick walls
Power Supply Stability	Ensure stable 3-phase power (usually 380V or 415V)
Cooling System	Adequate water pressure and flow for stable operation
Integration Capability	Match control system to your line’s PLC or automation
Local Support	Choose a supplier who offers local installation, training, and spare parts

🛠️ How to Use a 200kW HF Welder (Basic Steps)

Start Cooling System: Ensure water flow to the generator and induction coil is active and stable.
Power On: Use the control cabinet to start the generator and set power levels.
Align Induction Coil or Contact Tips: Position them precisely around/near the pipe seam.
Start Line Operation: Feed the strip through forming mill; edges should meet at welding point.
Adjust Welding Parameters: Fine-tune power and frequency to optimize seam fusion.
Monitor Quality: Check for smooth, complete welds with minimal burr or spatter.
Routine Maintenance: Clean filters, inspect the coil/tips, and replace impeder rods regularly.

List of Equipment Supply

🧩 Main Components of a 200kW HF Welder System

Component	Function
HF Power Generator (200kW)	Generates high-frequency current using solid-state IGBT or MOSFET modules
Matching Transformer	Matches the impedance between the power supply and welding load
Induction Coil / Contact Head	Transfers HF current into the pipe seam area
Impeders	Ferrite rods inside the pipe to concentrate current at the weld edges
Cooling System	Circulates water through generator and coil to prevent overheating
PLC Control Cabinet	Digital interface for controlling power level, fault display, and operation
Water Recirculation Unit	Provides clean, pressure-regulated water for cooling system

Designed Parameters for 200kw HF welder

Item	Specification
Rated Output Power	200 kW
Output Frequency	150–400 kHz (adjustable depending on pipe specs)
Input Voltage	380V / 415V ±10%, 3-phase, 50Hz / 60Hz
Power Efficiency	≥ 85% (solid-state design)
Cooling Method	Water cooling (for generator, transformer, coil)
Water Pressure	≥ 0.2 MPa (recommended: 0.3 MPa)
Water Flow Rate	60–80 L/min (depending on usage and ambient temp)
Welding Speed	Up to 40–60 m/min (depending on material and size)
Control System	Digital PLC + HMI (touch screen)
Output Mode	Constant power / automatic load tracking
Cooling Water Inlet Temp	≤ 35°C
Working Ambient Temp	0–40°C
Relative Humidity	≤ 90%, non-condensing
Dimension (Generator)	Approx. 1500mm × 1000mm × 1800mm
Weight	~1200–1500 kg (varies with configuration)

How to Select the Right HF Welding Machine

Selection Criteria	Recommendation
Pipe Diameter and Wall Thickness	Ensure the machine’s power and frequency match the range of your product.
Welding Speed Requirements	Higher power allows faster production lines. Check your line's speed capabilities.
Material Type	Steel, stainless steel, or alloy — some materials require more stable energy input.
Production Volume	For continuous production, choose solid-state machines with high reliability.
Integration Needs	Consider compatibility with your existing PLC or automated systems.
Cooling Conditions	Check factory water supply and temperature stability for the cooling system.
Service & Support	Choose suppliers who offer local support, spare parts, and commissioning services.

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200kw Solid State Welders FAQs

What pipe sizes can a 200kW HF Welder handle?

Typically depending on material and production speed.

Is solid-state better than vacuum tube HF welders?

Yes. Solid-state welders have: Higher energy efficiency (up to 90%) Longer service life Lower maintenance Smaller size and better automation compatibility

What happens if the coil is misaligned?

Misalignment causes uneven heating and poor weld quality — always ensure the coil or contact head is centered and parallel to the pipe seam

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