TPT January 2007

P rogress in W elding T echnology, E quipment & C onsumables

Compact welders based on IGBT technology and MES systems

EFD Induction, Norway, a leading supplier of induction heat solutions and a forerunner in solid-state induction technology, is renowned for its Weldac (Elva) welders and patented IGBT inverter technology. With fully automatic electronic load matching, it is claimed that the Weldac is one of the most reliable induction welders on the market. The company has recently introduced a larger 600kW single-cabinet welder. Measuring only 22" (570mm) longer and 4" (100mm) taller than the company’s popular Weldac 300, the Weldac 600 is one of the most compact welders of its size available. This new Weldac joins the original single- cabinet induction tube welder (300kW max power rating), launched by EFD to acclaim in 2003 and believed to be a world first. The technical excellence of these welders is due to a new method of deploying the very rugged IGBT transistors at the high frequencies required in many welding applications. The uptime of the new Weldac series is significantly increased compared with solid-state welders using today’s predominant Mosfet technology.

EFD Induction’s patent makes it possible to use fewer, cheaper and more rugged transistors, known as IGBTs, in Weldac’s high-frequency power modules. This makes the entire system less costly and more reliable. The new Weldac can be delivered with output power levels from 150kW to 2,000kW, with a frequency of 80-350kHz. To date, EFD has delivered fifteen Weldac systems within the power range of 1,000kW to 1,800kW; two of these systems are 1,800kW induction welders. Baoshan Iron & Steel Co Ltd, Shanghai, is currently running a Weldac 1800 solid-state welder and two seam-annealing systems (both 2,400kW). The seam annealing systems perform annealing, quenching/normalizing and quenching/tempering with a total seam annealing power of 4,800kW. The installed systems contain six units, all equipped with automated orbital tracking systems to follow the weld seam. The equipment produces tubes up to OD 24" with a WT over 20mm. Because of the modern man/machine interface and the IGBT Inverter technology,

› The Weldac 1800-for API pipes up to 26" OD

EFD’s welders and annealers are extremely easy to operate, and include the latest control system technology to meet the demanding needs for better quality control and traceability of finished products. Manufacturing Enterprise Systems (MES) are currently in increasing demand. The MES system collects information from the entire production line and stores it in a database. The collected information includes a range of details on the product quality or production line efficiency. Information is usually collected automatically from the production machines, although operators can also input information. The MES system is part of the plants Quality Assurance System. When a product is finished, the MES system can provide quality certificates including vital production data. MES data can be used to analyse product history if it is found to be defective after delivery. MES information is also used to analyse and improve production efficiency. Tube welders and annealers from EFD have been delivered with interfaces geared towards MES systems. The interface is usually Ethernet based, and provides production data including weld current, weld power, and annealing temperature etc. Detailed status information from EFD’s machines are thus provided for MES. EFD Induction’s Weldac and EFD annealing systems are now able to cover OD ½" to OD 26" of tube production, from the smallest to the largest tube sizes. EFD Induction – Norway Fax : +47 35 50 60 10 Email : pru@efdgroup.net Website : www.efd-induction.com

Light reactive welding helmets The Starparts division of industrial equipment supplier Wilkinson Star Limited, UK, has launched a new range of Beta light reactive welding helmets. The range of designer style helmets are lightweight, weighing only 602g, and are available in three solid colours and in six striking multi-coloured versions.

Each helmet is supplied with an integrated normal shade DIN #3.5 and variable shade control from DIN #9 to 13. The power for the light reactive shades is provided by a 3v x2 CR2032 battery and a solar powered cell, and a warning light informs the welder when the battery is low. Two optical sensors identify the welding arc, and the shade reaction time is 1/20,000 second. An adjustable delay allows the wearer to ensure that they receive no light emission from the completed weld. The helmet also has a low/ high sensitivity control, and a fully adjustable headband. The welder’s viewing area within the helmet is 98mm x 46mm.

› Wilkinson Star’s new range of light reactive welding helmets feature a shade reaction time of 1/20,000 seconds

CE marked and ROHS compliant 2002/95/EC, the helmets are supplied with two spare clear covers for inside and two spare clear spatter protection visors for the front.

Wilkinson Star Limited – UK Fax : +44 161 727 8297 Email : alistair.baker@wilkinsonstar.com Website : www.wilkinsonstar.com

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J ANUARY /F EBRUARY 2007