Design concept: Ribbed square tubes and the welding of ribbed square tubes: As the products to be welded are hollow square pipe and have coating, four welding transformers are required (four welding spots arranged in the middle, configured with two transformers for double-sided single-point welding, one transformer for double-sided single-point welding on two sides and one side, with two cylinders mounted on both sides of the transformer; if seven welding spots are required, this transformer will complete product welding in two cycles). Welding speed requirements: No less than 40 pieces per hour; Welding spots present a neat and aesthetic appearance. In order to ensure stable welding quality and high production efficiency, our company puts forward a targeted solution based on rich technical experience and customer actual demands: Adopting gantry welding principle with high-power and high-energy welding current; medium frequency inversion welding is prioritized for its outstanding current density performance; the rigidity of electrodes and fixtures as well as the guiding precision of the machine frame are designed to outperform conventional gantry welders.
Custom double-feed welding molds are adopted to integrate welding procedures and material arrangement, fully utilizing the idle waiting time caused by single-mold operation in traditional processing and effectively boosting overall welding output. Tailored for supporting IBCs Production Line assembly demands, our company has developed a professional medium frequency inversion double-mold protective cage welder. This dedicated unit belongs to mature Automatic Welding Machine for ribbed square tube protective cage fabrication, mainly consisting of gantry frame, medium frequency inversion control system, electric operation system, special matched transformers, dedicated welding pressurized cylinders, upper and lower electrode assemblies, double-feed mold racks, cooling circulation system, pneumatic system, monitoring device and safety protection mechanism.
## Equipment constitution
Designed with standard Automatic Type working mode, the equipment mainly comprises gantry machine body, medium frequency inversion constant current welding power supply, electric operation system, special welding pressurized cylinder, upper and lower electrode components, double-mold base frame, water cooling system, pneumatic system, monitoring device, safety mechanism and other assemblies, with detailed introduction as follows:
1. Machine body: The vertical reinforced structure is fabricated by high-quality thick steel plate welding, fitted with rationally arranged reinforcing ribs and processed by stress relief treatment. It delivers excellent mechanical performance with slight deformation and superior structural toughness during long-term operation.
2. MF inversion DC welding power source is mainly composed of transformer, controller, inverter, power driver, rectifier assembly, capacitor plate, IGBT and core central control parts. As advanced and widely applicable welding equipment, the medium frequency inversion constant current welding power supply features compact welding transformer size yet high energy output. It converts the original 50/60Hz input frequency to 1000Hz, and the rectifier diode in the transformer secondary loop converts power into constant current supply, greatly optimizing the secondary circuit reactance coefficient — a key factor leading to energy loss in traditional equipment. This design achieves nearly ideal matching in constant current welding loop, cutting down production costs to the maximum extent. Compared with conventional welding power source, it has the following
| Advantages | Save energy |
| Improve the power factor and reduce production costs; |
| In the secondary circuit with large opening area, interference can be reduced and welding current is constant current. When the secondary winding has inductive materials (with magnetic property), it will not affect the welding |
| make a balance of the loading of power supply device, medium frequency inversion constant current welding power source uses three-phase power and stores energy |
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