SAI AUTOMATION TECHNOLOGIES

Kavi Nagar, Ghaziabad, Uttar Pradesh

• Sai Automation are prominent manufacturer of solid State HF Welder in India & range from 50KW to 1200KW

• Sai automation offers the most modern Solid State HF Welder with energy efficiency more then 85%. There are saving in energy and thereby reduce the production cost and can easily handle wide range of incoming voltage fluctuations. These welders are 100% protected against coil arcing short circuiting.

• Sai Automation Solid State HF Welder requires very minimum maintenance ensures smooth and troble free production. A Touch screen display on the operating control desk gives the operator complete information of the welder extensive fault diagnose system in case of a breakdown.

Sai Automation welders are most suitable for welding of pipe and tube from 8mm-300mm. For small diameter use induction welder and contact welders are suitable for large diameters.

A Sai Automation induction welder at full output achieves 2%-3% energy saving, over a welder with fixed output transformer.

Sai Automation welder are designed for continuous operation to perform under most hostile environment.

Each welder consists of a Hartley or colpitts type oscillator circuit, with grounded cathode design to reduce voltage stresses on oscillator components.Each welder components like power supply cubicle, oscillator cubicle and heat exchanger has been designed and built to rigorous standards to ensure reliability and product life. Every welders are thoroughly tested at dummy load prior to dispatch, ensuring minimum erection and commissioning time.

Easy Accessibility

The power supply and Oscillator cubicle are housed in separate cabinets. Therefore the power supply cubicle can be located away from welding area and oscillator cubicle should be located as close as possible welding area. Both cubicles dust and vermin proof and contain internal air/water heat exchanger to maintained all components cooling at required temperature.

The closed circuit distilled water cooling circuit is made of copper tubes with crome plated and best quality rubber hose pipes to prevent any galvanic corrosion within the equipment.

Standard Protections

• Magnetic short circuit (provided in the main supply MCCB).
• Instantaneous electronic over current trip.
• Instantaneous DC magnetic over load relay.
• Ambient temperature thermostat.
• Magnetic float type water flow switch.
• Thyristor over temperature thermostat.
• Metal oxide varistors in the incoming lines to protect thyristors from high voltage transient in the main supply.
• Spark Gap to protect oscillator valve and other components.
• Earth droppers.
• Electromechanical door inter lock in high voltage compartment.
• Input water over temperature thermostat.
• Oscillator valve output temperature thermostat.
• Oscillator valve seal over heat.

Major Components Of Hf Welder

• Compact and separately sealed enclosures for power supply and oscillator cubicle.
• Moulded case circuit breaker with short circuit breaker.
• Triple pole power contactor of suitable rating for disconnecting the mains supply.
• Closed loop Thyristor (SCR) power control system. By controlling the phase angle of the thyristors, the welder output can be adjusted from zero to maximum step lessly and at the same time welder output is stabilized to +/-1% for an input voltage variation of 10%.
• Programmable logic control (PLC) used for complete control circuit (optional).
• Alphanumeric digital display for fault diagnostic information and on line welder Parameters (optional).
• Meters is mounted on the door of the power supply cubical and operating control desk.
• Oil cooled high tension plate transformer. The Transformer has high impedance so as to limit the short circuit current to a max. of 10xI rated. It steps up the thyristor controlled main AC voltage into high voltage AC to feed the high voltage rectifier.
• Low ripple LC Filter. It is incorporated so as to bring down the ripple content in high voltage DC supply.
• DC High voltage rectifier with silicon diodes. It rectifies the high voltage AC power from the H.T. transformer to the DC power required for the oscillator.
• Magnetic overload relay.
• Plate & grid choke.
• Water cooled metal-ceramic oscillator valve.
• Water cooled ceramic tank capacitor.
• Grid bias disc capacitors.
• Water cooled grid bias resistance assembly.
• Oscillator valve filament voltage regulator. A single phase closed loop thyristor control voltage regulator is provided to regulate oscillator valve filament supply. The filament supply is stabilized to +/- 2% for an input supply variations of +/-10%. Filament voltage is gradually set by a built in ramp circuit.
• HF Transformer.
• Water flow switches
• strainless steel plate type heat exchanger with Non ferrous pump and PVC Tank all assembled on a steel frame and interconnect with copper pipe line for distilled water circuit.

Sai Automation make DC Drives are highly sophisticated and provided with adjustments which are factory set and may require only slight re-adjust at the time of commissioning.

The drive is supplied normally in two parts i.e. DC Drive panel & one Pendent box.

DC Drives has been specially designed, it must be installed in all area, where the following conditions exists:

• Ambient temperature does not exceed 45 0 C & it is not less than 10 0C .
• Ambient air is reasonable clean & dry and must be free of flammable or combustible vapours, steam or corrosive gases.
• Attitude should be 1000 meter above sea level maximum.
• The clearance around the cabinet must be enough to provide full accessibility to the front and back side. Also Provide a non-restricted airflow from the intake and exhaust ventilation lowers.

Features

• High speed fuses in the incoming lines for protection of thyristors.
• di/dt protection
• dv/dt protection
• Surge suppressor across each thyristor
• Electronic single phase protection
• Electronic instantaneous over current trip
• Over temperature protection for thyristor
• Current sensing type field loss relay

Sai Automation offer automatic PLC Controlled panel as per requirement of customer for pipe and tube production. Programmable logic controllers (PLC) Controlled panel are easy to operate and possess salient features such as digital and analog inputs, relay output, timers, counters, time switches, and auxiliary relays.PLC are designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing was accomplished using hundreds or thousands of relays, cam timers drum sequencers, and dedicated closed-loop controllers. The process for updating such facilities for the yearly model change-over was very time consuming and expensive, as electricians needed to individually rewire each and every relay.

Early PLCs were designed to replace relay logic systems. These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. This program notation was chosen to reduce training demands for the existing technicians. Other early PLCs used a form of instruction list programming, based on a stack-based logic solver.

Sai Automation provide digital DC Drive panels for DC motor control application with complete accessories and devices such as Mains MCCB, High speed fuses, Input- chokes, Digital Drive module of various makes such as Siemens, Schneider, Control technique and other make as per customer choice. We not only provide excellent quality and workmanship but also provide service support to customers by way of designing the operation and service manual.Digital DC Drive panels are easily adaptable to communicate with a local network or Ethernet. The bridge is easily accessible from the front for maintenance and all high voltage components are protected by safety barriers. These drives combines powerful performance with flexible control to produce a highly functional, cost-effective drive and control solution.

Technical feature

• Advanced microprocessor technology
• Programmable regulator, PLC
• Connectivity to various operator interfaces including touchscreen
• Full four quadrant SCR bridge
• Series or shunt type systems
• Regenerative braking
• Electronic armature reversing
• Automatic field weakening

Sai Automation provide AC Drive panels for motor control application with complete accessories and devices such as Mains switch, MCCB, Input-Output chokes, VFDs of various makes such as ABB, Siemens, Mitsubishi, Schneider, Danfoss and other make as per customer choice. We not only provide excellent quality and workmanship but also provide service support to customers by way of designing the operation and service manual

Introduction
An AC drive is a device that is used to control the speed of an electrical motor, either an induction motor or a synchronous motor. AC drives are also known by various other names such as adjustable speed drives (ASD) or adjustable frequency drives (AFD) or variable frequency drives (VFD) or variable speed drives (VSD) or frequency converters (FC).The speed is controlled by changing the frequency of the electrical supply to the motor. The 3-phase voltage in the national electrical grid connected to a motor creates a rotating magnetic field in the motor. The rotor of the electrical motor follows this rotating magnetic field. An AC drive converts the frequency of the network to anything from 0 up to 300 Hz or even higher, and thus controls the speed of themotor in proportion to the frequency.

Technical feature

• Sensorless Vector control frequency inverter with high performance, excellent quality and low pollution.

• It achieves quick-response and precise control by decoupling control of motor magnetic flux current and torque current, which makes the speed adjustment and torque control runs at a high degree of accuracy and wide range.

• Advanced processing technique and perfect testing equipment, which guarantees the applicable reliability.