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Induction pipe bending project for BYD

Jan. 06, 2025

In 2018, BYD Auto not only conquered the EV market, but also expanded its commercial field to the construction of urban light rail. ShanWei BYD Auto Co., Ltd. vigorously developed the design, testing, manufacturing, and installation technology of urban light rail during this period. At that time, a light rail construction project undertaken by BYD had high requirements for the load-bearing capacity of the curved structure of the track part. Traditional cold bending, hydraulic bending, and coiling technologies either could not accurately control the curvature radius or could not eliminate internal residual stress. Therefore, this bending technology has certain difficulties and requires experienced, technically mature, and reliable induction heating manufacturers to achieve the goal of rapid bending, precise control, and structural stability. Duolin is such a manufacturer Successfully solved BYD's urgent need.

BYD's requirement is to use induction heating to bend Q235 steel pipes with a length of 9m and a radius of 219-529mm at a speed of 0-5mm/s. The final bending radius is 5000-20000mm.

Obviously, this is not simple. Our technical team has conducted multiple technical verification and self purchased materials for internal testing, quickly verifying the technical feasibility and achieving the established testing goals in a short period of time.

In the end, our plan won the favor of BYD and secured this order.

The solution proposed by our design team is:

① The steel pipe bending and pushing method adopts hydraulic cylinder pushing, and the longest 9000mm steel pipe is bent and formed in one push without any pause operation in the middle. The length of the rotating arm is electrically adjustable, and the adjusted length of the rotating arm is displayed on the PLC screen.

② Equipment:

IGBT medium frequency induction heating equipment, with a power of 350KW and a working frequency of 0.5-8KHz, is matched with a transformer capacity of 3000KVA, as well as a closed water cooling system and induction coils with corresponding different bend diameters. The hydraulic pipe bending machine is controlled by PLC.

③ Function:

Alarm functions: high temperature alarm, low cooling water pressure alarm, motor fault alarm.

Setting function: It can save the temperature, speed, angle, wall thickness, diameter, and radius of induction heating, making it convenient to directly retrieve parameters for the next induction bending.

Automatic function: After setting the parameters, the induction bending machine adjusts the speed through internal PID to achieve constant temperature bending.

Our advantage is

① All components are made of internationally renowned brands, such as Fuji for IGBT modules and Hankook for internal rubber water pipes.

② IGBT heating efficiency is higher than that of medium frequency power supply equipment using thyristors, saving 10% energy compared to thyristor medium frequency power supply.

③ Modular design, easy to maintain.

④ The output capacitor is installed inside the intermediate frequency power supply. When bending steel pipes of different specifications, only the transformer turn ratio needs to be adjusted, and the output capacitor does not need to be adjusted, making it more convenient to use.

⑤ Neat and reasonable wiring ensures that the equipment has good anti-interference ability and reduces interference with other devices.

⑥ The working and fault indicator lights on the circuit board not only display the working status, but also facilitate the search for faults.

⑦ Isolate waterways and circuits to avoid electrical malfunctions caused by water leakage.

⑧ The power factor of IGBT medium frequency induction heating power supply is high (0.95-0.98), with minimal interference to the power grid and no need for compensating capacitors.

⑨ Low noise and minimal harm to workers.

⑩ High energy conversion rate and fast heating speed

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The induction bending pipe power supply equipment has passed electromagnetic compatibility and low voltage testing in a third-party laboratory in Chengdu and obtained CE certification.

The on-site trial run was surprisingly successful, and BYD highly appreciated the professionalism of the DoLin team. This project is also another strong proof of DoLin's mission of "solving customer difficulties and providing a complete set of solutions"


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What is induction Heating?

What is induction Heating?

Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, through heat generated in the object by eddy currents. An induction heater consists of induction power supply (induction heater) and inductor (coil) that is a shaped to contour the part, and a work station where the part is held and presented to the coil.

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