01 - ac-dc power wave overview

7/31/2019 01 - AC-DC Power Wave Overview

1/16

1

AC-DC Power Wave 1000A


2/16

2

Key Features I

Modular System with 1000A units @ 100%Duty Cycle

Easy Paralleling of up to five 1000A units toachieve necessary Currents

Same Hardware can be used for AC, DC+ orDC- Process with CC or CV characteristic.

Even Phase Generator has same hardwarethan Power Wave PC.-Board Less Spare Parts


3/16

3

Hardware Overview


4/16

4

Key Features II

In Multi-Arc Environment all arcs are syncedby an external Phase Generator

The Phase Generator allows infinitelyvariable Frequency and Phase Shift betweendifferent Arcs or different Frequencies foreach arc

Square Wave Process can use Wave FormControl Technology to adjust Balance orDC-Offset


5/16

5

Wave Form Control Technology


6/16

6

Independent Wave Form

Parameters for each Arc Phase Angle: Stepless changeable

Frequency: Stepless changeable (10Hz to

90Hz - upper frequency can change withinductance of welding cable)

DC Offset: Positive vs. Negative Amplitude

Balance: Positive vs. Negative Cycle Time

Slope: Fixed within Wave Form description


7/16

7

Idea of Wave Form Control

Stepless change of Melt of Rate vs.Penetration with no effect on the Heat Input

Calculation

s

i

ii

v

IU

HI

=

1000

60

HI = Heat Input [kJ/cm]

U, I = Voltage and CurrentWorkpoint of each

Arc

v = welding speed [cm/min]


8/16

8

Usage of Wave Form Control


9/16

9

Comparison to Standard

Equipment Power Wave AC-DC

DC+, DC-, Sinus,Square Wave or

Custom Wave Form Variable Frequency

Variable Phase Shifting

Transformer or Rectifier

Only DC or Sinus WaveForms

Frequency fixed toPower Supply

Phase Shifting limited to

60, 90 or 120


10/16

10

Comparison to Standard

Equipment Power Wave AC-DC

Power Factor 95%

Efficiency Rating 86%

Transformer or Rectifier

Typical Power Factor65-95% Rectifier or

40-80% Transformer Typical Efficiency

Rating 70-80% Rectifieror 80-85% Transformer


11/16

11

Standard SAW Processes

DC+ or DC- (CC or CV)

Square Wave with Wave Form Controls (CC

and CV) Sinus Wave Form fixed at 50Hz and 60Hz

only (only CC) to emulate standardTransformers

Additional Wave Forms possible at CustomerRequest


12/16

12

Networking with Power Wave


13/16

13

Network Overview

Daisy Chain Connection of Digital Bus runsfrom Phase Generator to Master to Slave

Power Waves Device Net Interface adds possibility of easy

PLC connection

Ethernet Network between all Power

Sources, Phase Generator and ControlCenter


14/16

14

PLC Interface

Device Net Interface to Allan Bradley PLC(or Siemens with additional Gateway)

Independent control of each Arc On the fly changes of Welding Work Points

Report of Power Wave and Arc Status(Current, Voltage, WFS, Diagnose Bits)


15/16

15

Command Center

Detailed Set up of Power Wave Parametersincluding Strike, Start, Burnback and Crater

Fill


16/16

16

Command Center

Detailed Diagnose of every single PowerWave

01 - ac-dc power wave overview

Documents