The induction furnace is a frequency conversion device that converts three-phase power frequency current into single-phase intermediate frequency current. It can cause eddy current loss of metal through electromagnetic field induction to achieve the purpose of heating and melting. It is used for smelting, heating, and heat preservation of ferrous or nonferrous metals and alloy materials such as steel, copper, aluminum, etc. It is mainly used in metal casting and steelmaking industries.
We can provide customers with complete sets of equipment production lines including a smelting system, cooling system, dust removal system, automatic batching and feeding system, and pouring system.
The diversity of products and different cost-performance ratios give you more choices and experiences.
1. Characteristics
This set of equipment can realize automatic remote control, and also includes PLC programmable controller, HMI human-machine interface or industrial control computer system, industrial control configuration software, and various sensors. It can realize automatic constant temperature, automatic oven drying, puncture-proof alarm, and other automatic operations, making it safer and more convenient to use!
Double power supply design with high efficiency and energy saving series connection of one driven two (one furnace for smelting and one furnace for heat preservation)
Series IF series power supply can realize single power supply, dual power supply, and multiple power supply configurations.
Among them, the new type of
medium frequency smelting furnace with one driven two in series has the function of a set of medium frequency power supplies pulling two furnace bodies to work at the same time. The utilization rate of the equipment reaches 100%. Only by adjusting the power knob (or digital operation screen), the total power of the intermediate frequency power supply can be distributed between two furnaces at will to achieve the effect of melting one furnace body and heat preservation of the other. It can realize the one-time casting of large castings or a continuous supply of molten iron to the production line. The continuous smelting mode has greatly improved the production capacity and is energy-saving and practical, which has been accepted and loved by customers.
Advanced Computer Management System for Melting
The on-site smelting computer management system, digital main control board, PLC, and other equipment form a network system, which can be expanded to control and manage in the office through the switch. With an Ethernet port, USB interface, and unique IP address, it can realize data collection, transmission, and monitoring of equipment anywhere in the world, providing you with remote diagnosis and rapid and timely troubleshooting.
The full digital on-site smelting control system can realize automatic constant temperature, automatic oven drying, power distribution display, intelligent smelting management, fault information display and storage, and other automatic operations.
This set of equipment can be fully automatically controlled. It also includes PLC programmable controller, HMI human-machine interface or industrial control computer system, industrial control configuration software, and various sensors. It can be configured with foundry equipment and operations and connected with various tools, including a remote display, temperature measuring instrument, thermal analyzer, spectrometer, demand controller, and large screen display. It is safer and more convenient to use!
When the intermediate frequency power supply cabinet is placed in the basement and the remote operator console is placed on the furnace platform, other functions such as starting, stopping, and resetting of the intermediate frequency power supply can be realized. The remote console is equipped with a large size touch screen. The PLC and human-computer interface form a convenient on-site smelting manager. Its functions include automatic oven drying, cold furnace startup, fault diagnosis, fault information display and storage, operation information display, system status display, etc.
The fault detection (protection) display tracks and protects the equipment in operation in an all-around and real-time way. When it detects abnormal value information such as load short circuit, overcurrent, overpressure, insufficient water pressure, and excessive water temperature, it will feed back to the control system in time to realize automatic shutdown protection and prevent accidents from happening. In addition, damaged components such as silicon-controlled rectifiers, compensation capacitors, and voltage transformers will automatically stop and light up corresponding indicator lights.
2. Induction Furnace Diagram
(1) The induction furnace body is designed with two dust removal systems, namely, the dust hood and dust ring.
The dust hood (ring) can absorb the dust and waste gas generated in smelting through a certain amount of airflow, so as to achieve and improve the effectiveness of waste gas emission. It is designed to meet the requirements of environmental protection and environmental impact assessment. Users can choose the configuration according to their needs.
The induction furnace cyclone dust hood has an excellent dust collection effect, takes up less space, and can be tilted back and forth and operated at any position. It is suitable for fully automatic feeding and discharging operations in the foundry.
Compared with the cyclone type, the side suction dust ring has no forward and backward tilting movement mechanism and is easy to install. It is suitable for semi-automatic or manual feeding and discharging operations where the foundry cannot use the dust hood due to some feeding methods.
(2) Fully intelligent automation and humanized function design
★ Furnace tilting oil cylinder system:
Including hydraulic pump station and furnace tilting console. It is designed for full-load furnace tilting and consists of a hydraulic pump and drive motor, emergency pump, motor starting device, oil tank, oil return, and oil suction filtering device (with explosion-proof valve device). The tipping, stopping, and resetting of the furnace body are realized through the buttons and handles on the hydraulic operation platform. The furnace body can be tilted 95 degrees by the push of the hydraulic cylinder to pour out all the metal liquid and can stay at any position during the tilting process as required.
★ Furnace change switch:
The furnace change switch is an electric fast switch used in the medium frequency electric furnace: easy to operate, safe, and reliable!
★ Automatic constant temperature function:
The required range value of boiler water temperature can be set in advance, and automatic constant temperature can be realized by one key startup; Compared with the traditional manual temperature control, the automatic constant temperature function will save time and trouble, be more sensitive, and accurate, the furnace water temperature will be easier to control, the oxidation and burning loss will be less, and the metal composition will be even and the product quality will be better!
★ Automatic oven drying function:
Oven drying is a relatively complex and long-curve heating process. To prolong the service life of the intermediate frequency furnace and reduce production costs, the correct furnace building and drying process is essential. The company's innovative automatic oven drying function can preset the time and temperature required for different oven drying stages according to the requirements of different furnace lining refractory materials; According to the preset time and temperature values of the PLC, the one button startup can automatically match and infinitely adjust the size of the intermediate frequency power, control the heating rate, prevent the furnace lining from cracking, and achieve the goal of automatic curve drying. That is to avoid manual misoperation and reduce the labor time and intensity of workers.
★ Furnace puncture alarm function:
The dual anti-penetration alarm function adopts the dual combination detection of differential current mode and DC injection mode. It provides the furnace system with extremely reliable fast protection against furnace leakage and any grounding fault. The detection system has an early warning function. When the furnace lining thins to a certain extent, it will give an alarm with a warning light in advance to remind the user that the life of the furnace lining is coming, and predict the furnace penetration in advance to achieve the purpose of safe production. Solve the problem that customers can't start the machine because they have been using it all the time, and there is material in the furnace that can't continue to melt.
★ Furnace weighing function:
According to customer requirements, a weighing system can be installed in the furnace body, and the hot metal weight data can be transmitted to the operating platform PLC and displayed through the touch screen, which is convenient and intuitive to reflect the current weight of molten liquid in the furnace body, and convenient for the operator to adjust the composition and arrange the output. At the same time, the system can realize automatic smelting. It can automatically control the weighing and distribution of the furnace charge according to the formula of the material list of each brand, automatically compensate the error, automatically alarm the out of tolerance, and print and record the batching data, with high batching accuracy and speed; The accurate ingredients ensure the stability of the molten iron composition and provide a strong guarantee for the production of high-quality molten iron!
★ Furnace lining pushing out structure:
Once the furnace temperature is cooled to below 400 ℃, turn the furnace body to 90 °, lift the push-out oil cylinder with a crane, place the connecting flange of the oil cylinder in the pre-designed guide rail at the bottom of the furnace, start the hydraulic pump station, and easily push out the furnace lining. The work intensity is reduced and the work efficiency is improved.
3. Guide for Selection of Medium Frequency Electric Furnace
The diversity of products and different cost-performance ratios give you more choices and experiences:
(1) The Development Course and Comparative Selection of Intermediate Frequency Power Supply
First generation: KGPS thyristor parallel IF power supply
It is the most widely used in the past 20 centuries, with low prices and cheap accessories.
High energy consumption, power consumption per ton of molten steel is about 650 degrees. Adjust the power by adjusting the DC voltage, the power factor is low ≤ 0.90, and there is harmonic interference, which has varying degrees of influence on the operation of the reactive power compensation capacitor in the substation.
Second generation: KGCL silicon-controlled series intermediate frequency power supply
It is an upgraded version based on the first generation KGPS parallel medium frequency furnace in the past 20 years, which can save about 15% energy compared with the first generation KGPS parallel inverter power supply (about 550 kWh power consumption per ton of molten iron).
Third generation: new energy-saving IGBT module series IF power supply
It is a revolutionary innovation of the latest energy-saving product, subverting the previous traditional silicon-controlled intermediate frequency power supply structure; IGBT integrated module (transistor) is used for frequency modulation, power regulation, and full wave rectification; It is not affected by the amount of furnace charge and the thickness of furnace lining, and maintains constant power output throughout the smelting process. The energy-saving IGBT transistor medium frequency electric furnace can save energy by 15% - 25% (about 470 kilowatt hours per ton of molten iron) compared with the traditional silicon-controlled medium frequency power supply.
The main reasons for energy saving are as follows:
A. The inverter voltage is high, the current is small, and the line loss is small. This part can save about 15% of energy. The inverter voltage of the energy-saving IGBT transistor intermediate frequency power supply is 2800V, while the inverter voltage of the traditional silicon-controlled intermediate frequency power supply is only 750V. The current is nearly 4 times smaller, and the line loss is greatly reduced.
B. The power factor is high, the power factor is always greater than 0.98, and the reactive power loss is small. This part can save energy by 3% - 5% compared with the thyristor medium frequency power supply. Since the energy-saving IGBT transistor intermediate frequency power supply adopts the semi-controllable rectification mode, and the rectifier part does not adjust the thyristor conduction angle, the power factor is always greater than 0.98 throughout the working process, and the power loss is small.
(2) Comparison and Selection of Steel Shell Furnace and Aluminum Shell Furnace:
The hydraulic station tilting device is adopted for the steel shell furnace body; The furnace body is welded with a high-quality steel structure, which is more safe, firm, and more durable; The inductor is enclosed by a magnetic yoke with a coverage area of more than 65%. Because of small magnetic leakage and high efficiency, it can save nearly 5% energy consumption compared with aluminum shell furnaces. It is equipped with a leak-proof furnace alarm device, which can predict the furnace penetration in advance to achieve the purpose of safe production. The steel shell furnace body is designed with two kinds of dust removal systems, namely, a smoking hood and a smoking ring, which meet the requirements of environmental impact assessment. Users can choose the configuration according to their needs.
The aluminum shell furnace body adopts a reducer furnace tilting device; The furnace body is made of alloy aluminum by sand casting; Low price, easy maintenance, and observation. The disadvantage is that the efficiency, service life, and safety are relatively low, and the electromagnetic radiation is not shielded. As there is no smoking and dust removal device for the aluminum shell furnace, some local government departments have ordered the user to replace the aluminum shell furnace with a steel shell furnace.
Looking for an induction furnace, please feel free to contact me.
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