When EFD Induction added a range of low-power (50-250 kW) welders to its popular ‘Weldac’ family, the company knew it was meeting a need in the tube and pipe industry. “Our market intelligence told us there was significant demand for a welder that combined the proven benefits of our Weldacs with smaller power outputs, but we could never have anticipated just how much!” says EFD Induction Sales Manager Peter Runeborg. “For example, in just two years these systems have come to dominate the US market for new induction profile welders.”
To mark the success of the new Weldacs, EFD Induction will be displaying a 250 kW model at this year’s Tube Düsseldorf event. “But more importantly,” says Runeborg, “visitors can learn how the welder’s IGBT transistors, patented switching technology and automatic electronic matching make it ideal for high-throughput welding.”
According to Runeborg, the automatic electronic matching is especially suited for profiles because such workpieces typically feature ‘cutouts’, places where the metal has been cut or stamped out. These areas of course produce major impedance changes. Obsolete welders attempt to handle these changes with voltage and current ‘over- kill’, but the result is often unsatisfactory weld quality.
“Automatic electronic matching is,” adds Runeborg, “one of the hallmarks of EFD Induction Weldacs. That we can now offer such a benefit in a low-power package is a real boon for manufacturers— and not just as regards weld quality. Productivity is boosted, too. For instance, the Weldac is faster by meters per minute at welding profiles than are laser and TIG alternatives.”
Runeborg is however keen to highlight that a physical welder is only half of any EFD Induction welding solution. “Yes, all Weldacs offer automatic matching, rugged IGBT transistors, and a high constant power factor of 0.95. But our customers also want the scheduled maintenance, genuine spares, operator training, logistical support, and the local presence that only a global player such as EFD Induction can provide. And don’t forget, only Weldacs offer a five-year warranty on all inverter modules—that’s how confident we are in these systems’ reliability.”
30% less power consumption
EFD Induction will also use Tube Düsseldorf to showcase some of the products and services available from Electronic Heating Equipment (EHE), the impeder, welder coils and scarfing specialist acquired by EFD Induction in 2012. Based in Washington State, EHEsupplies manufacturers worldwide with everything from Canticut internal scarfing systemsto induction coils and impeder clusters. “Having EHE aboard,” says Runeborg, “is greatnews for customers. It means the world’s best induction welder is now integrated with theworld’s best impeders, ferrite and scarfing solutions. And of course, EHE enriches us withits vast welder experience, the company after all makes and stocks the world’s largestrange of impeders.”
EHE will share a stand with EFD Induction, and plans to display a selection of its impedersand induction coils. “Visitors from the oil and gas industry will be particularly interested to learn more about EHE’s innovative ID scarfing system, where the impeders are fullyintegrated into the design of the ID mandrel,” says Runeborg. This innovation can reduce weld power consumption by up to 30 percent compared with other ID scarfing methods. Moreover, supporting the scarfing tool on a cantilever removes the need for internal rolls.This lets the mandrel cover a wide range of tube sizes and eliminates the problem of rolling weld spume or other debris into the tube wall. A typical Canticut unit can ID scarf and chop 8” through 16” pipe using a single mandrel.
Runeborg stresses that the coming together of EHE and EFD Induction makes it quicker and easier for manufacturers to get their optimum welder solution. “Sourcing from multiple suppliers is costly and time-consuming, and risks compromising the system’s overall efficiency. With EFD Induction, manufacturers get one integrated solution covering everythingfrom coils to welders to seam normalizing and annealing systems.”
More than welding
EFD Induction will also be holding live demonstrations of a Minac 25/40 Twin mobile induction heating system. “An EFD Induction Minac always draws a crowd,” says Runeborg. “And it’s easy to see why. Visitors are usually amazed at the speed, ease and safety of operation, and the fact that one power output can, for example, be brazing copper while at the same time the other output is shrink-fitting a steel ring.”
A hugely popular induction heating system worldwide—and instantly recognizable by its triangular shape—the Minac features automatic electronic matching that lets it handle virtually any electrically conductive material. “Versatility is what the Minac is all about,” says Runeborg. “It can be used as a standalone stationary system, it can be attached to a robot, it can be used with standard power outputs or with handheld transformers attached via long, flexible cables. It can be fitted with a special elongated coil and used to remove the huge bolts on power station turbine covers. It can even be loaded onto a helicopter and flown out to offshore oil and gas platforms.”
The EFD Induction / EHE stand will be staffed by some of the companies’ top welding and heating experts. “Our Tube Düsseldorf team,” says Runeborg, “represents decades of experience and expertise in induction heating and welding. They’ve dedicated their professional lives to the practical application of the amazing technology that is induction heating. So Tube Düsseldorf is a great chance for people in manufacturing to drop by and learn—not only about induction heating, but how we can help them use it to gain strong competitive advantages.”