This equipment is specifically designed and manufactured for brazing heating of motor rotor guide bars. It features strong professionalism, a high degree of automation, simple operation, excellent welding quality, and stressfree guide bars after welding, with no bar breakage. Based on the endring data provided by your company – outer diameter Φ242 mm, inner diameter Φ154.8 mm, thickness 15 mm – and the overall welding requirements for the rotor end rings and guide bars, we recommend the 200 kW mediumfrequency endring brazing equipment.

II. Technical Parameters of the Motor Rotor Guide Bar Welding Heating Equipment

Rated output power: 200 kW, equipped with an output transformer for isolation.

Rated input voltage: threephase 380 VAC, 50 Hz.

Resonant frequency: 6–10 kHz, with automatic tracking.
★4. Equipment efficiency ≥ 96 %, and power factor ≥ 0.96 (when output ≥ 50 % of rated power, measured as the ratio of output power at the transformer box to input power).
★5. Adopts the reactance analysis control method; the output current and power are stable and continuously adjustable over the ranges: output current 1 %–100 %, output power 0.2 %–100 %.

The equipment provides protection functions against resonant overcurrent, short circuit, DC overvoltage, resonant overvoltage, overtemperature, phase loss, unit imbalance, and reactance overlimit; also features power limiting, resonant voltage limiting, volthertz limiting, and temperature limiting.
★7. A stateoftheart 20 hp industrial water chiller is selected as the cooling source.
★8. Inductor: based on the structural characteristics of the motor end ring, a singleside flatbottom heating inductor is adopted; the heating area is embedded with highfrequency lowloss silicon steel laminations (flux concentrators) to improve heating efficiency.

The temperature sensor must be a German brand (Optris) shortwave infrared sensor specially designed for coppermetal measurement, with laser alignment.
★12. Heating time: total heating and welding time is 5–10 minutes; heating time and holding time can be set independently, and the heating ramp rate can be set and controlled.

III. Equipment Operation Process and Temperature Profile (The equipment manufacturer does not provide specific welding procedures; the welding procedures are to be supplied by the user.)
3.1 Welding process and selection of main parameters:
The welding resonant frequency of the motor rotor guide bar welding heating equipment is 6–10 kHz with automatic tracking. The temperature is heated to above the melting point of the brazing filler metal, with a heating temperature of about 850 °C. The selected filler metal (wire or sheet) shall have a melting point at least 60 °C lower than the melting point of the endring material. During welding, the inductor shall heat uniformly from the inside to the outside with slow preheating. The heating method is bottom heating, with the inductor positioned below the end ring to be heated. The end ring remains stationary during heating. The specific heating process is as follows: the end ring to be welded is hoisted from the preparation station onto the inductor of the brazing machine for positioning; then the motor rotor is hoisted onto the brazing machine (or the end ring and rotor are preassembled beforehand) so that the gap between the end ring and the guide bars meets the welding clearance requirement. Then the filler metal (wire or sheet) and flux (borax) are added. After the filler metal and flux are in place, automatic heating and welding are started according to the preset heating and process curve. After automatic welding is completed, the rotor is hoisted down, turned over, and the same process is applied to weld the other end.
3.2 Reference welding procedures that the user may consider (the equipment manufacturer does not provide specific welding procedures; the user shall provide the accurate welding procedures):
3.2.1 Option 1: Add flux and filler wire on both sides of the motor rotor end ring and guide bars, then start the equipment for heating. After the temperature reaches the holding temperature, the filler wire gradually melts. After a holding period, the equipment automatically stops.

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