1. Overview
The Induction furnace aluminum melting is widely used in the aluminum industry. The loss of aluminum melting in the medium-frequency aluminum melting furnace is smaller than that in the power frequency furnace; The efficiency of medium frequency aluminum melting furnace is higher than that of the resistance furnace; The medium-frequency aluminum melting furnace can increase the melting rate by increasing the power; At the same power, the medium frequency aluminum melting furnace has less noise and less smoke pollution than the power frequency furnace.
2. Composition
The induction aluminum melting furnace consists of a complete set of medium frequency power supply with a frequency of 2500HZ, compensation capacitance, furnace body, water-cooled cable, and reducer.
3. Parameters
Model | Rated capacity (T) | Rated power (KW) | Working temperature (℃) | Melting rate (T/H) | Frequency (Hz) |
GWJTZ0.3-160-1 | 0.3 | 160 | 700 | 0.25 | 1000 |
GWJTZ0.5-250-1 | 0.5 | 250 | 700 | 0.395 | 1000 |
GWJTZ1.0-350-1 | 0.8 | 350 | 700 | 0.59 | 1000 |
GWJTZ1.0-500-1 | 1.0 | 500 | 700 | 0.89 | 1000 |
GWJTZ1.6-750-1 | 1.6 | 750 | 700 | 1.38 | 1000 |
GWJTZ3.2-1500-0.5 | 3.2 | 1500 | 700 | 2.38 | 1000 |
GWJTZ5.0-2500-0.35 | 5 | 2500 | 700 | 4 | 1000 |
4. Differences between Induction Aluminum Melting Furnaces and Induction Iron Melting Furnaces
Aluminum is a non-magnetic material. During the whole smelting process, the magnetic field is very easy to diverge, so the yoke arrangement should be reasonable. First of all, the area of the yoke must be large enough and as long as possible to ensure that the axial and radial magnetic fields of the inductor have a sufficient edge. If the inductor is a two-section coil (parallel and reverse winding), the magnetic leakage at the middle seam should be considered. Secondly, the inter-turn distance of the inductor is not easy to be too large, and 8-12mm is appropriate.
5. Selection of Induction Aluminum Melting Furnace Lining
Because of the high frequency, the high vibration frequency of aluminum liquid, and the strong penetration of aluminum, the furnace lining is very important. Special lining for aluminum furnace shall be selected. Generally, the good lining can be used for more than 300 heats. When aluminum melts, the eddy current generated is very large. At the initial stage of melting, due to the irregular distribution of furnace charge, the power supply is subject to strong impact, and it is easy to burn out the silicon-controlled rectifier. Therefore, the impact resistance of the intermediate frequency power supply should be strengthened when making it.
6. Advantages of Induction Furnace Aluminum Melting
(1）Induction aluminum melting furnace is widely used in the aluminum industry;
(2) The aluminum melting loss of medium frequency furnace is smaller than that of power frequency furnace;
(3) The efficiency of medium frequency aluminum melting furnace is higher than that of a resistance furnace;
(4) The induction aluminum melting furnace can increase the melting rate by increasing the power;
(5) At the same power, the induction aluminum melting furnace has less noise and smoke pollution than the power frequency furnace.
7. Energy Loss during Induction Heating of Induction Furnace Aluminum Melting
(1) Heat loss caused by current flowing through the inductor: this loss is taken away by cooling water. This part of the loss is the main loss of the system, which is related to the structure of the inductor, the physical properties of the charge, and the heating frequency. This loss is often described by "electrical efficiency". Electrical efficiency is the ratio of the energy transmitted to the heated workpiece to the energy received by the inductor from the power supply.
(2) Heat loss: the loss caused by the heat dissipation of the heated workpiece to the surrounding, which is second only to the loss of the inductor. This loss is often described by "thermal efficiency", which is the ratio of the net heat of heating the workpiece to the total heat of the workpiece from the induction coil.
(3) Transmission loss: the loss caused by cables and buses supplying power from variable frequency power supply to load is generally 2%~7%.
(4) Conversion loss: the loss of converter elements, filter inductors, commutation inductors, and compensation capacitors in the power cabinet is generally 2%~5%.
(5) The efficiency of medium frequency aluminum melting furnace is 62%, the thermal efficiency can reach 75%, the frequency conversion loss is 3%, and the transmission loss is 5%.
8. Guide for the Safe Operation of Induction Furnace Aluminum Melting
(1) Before starting the machine, first check whether water, gas, and electricity are connected, and then carry out the following operations;
(2) Operators must prepare corresponding insulating shoes, gloves, etc.
(3) Operators must have corresponding electrician knowledge.
(4) Before equipment maintenance, the switch must be pulled off to disconnect the power supply, and then the discharge treatment shall be carried out, and then the maintenance board shall be hung, and then the maintenance shall be carried out again and again. If the live operation is necessary, more than two people must be present, but it is not allowed to operate with high voltage.
(5) Before starting, make sure that the water circuit is normal and all parts of the equipment are normal before starting.
(6) Turn on the first filament, turn on the second filament after five minutes, and then turn on the high voltage after five minutes.
(7) Before sending high voltage, make sure that the output regulating potentiometer is at the minimum position, and then send high voltage, and adjust the output voltage to the working voltage.
(8) After the workpiece is confirmed, press the heating button to make the equipment work, but no no-load heating is allowed.
(9) In case of any abnormal condition of the equipment during operation, the power must be disconnected immediately, and the equipment can only be operated after finding out the cause.
(10) After the equipment is finished, first disconnect the heating, then disconnect the high voltage, then turn off the lamp filament and disconnect the power supply.
(11) After the equipment stops working, you must wait five minutes before disconnecting the water source.
(12) During the operation of the equipment, if it is necessary to leave for temporary reasons, it must be done. It is not allowed for people to leave the machine and stop. The machine is still working when there is no one.
9. Maintenance Guide for Induction Furnace Aluminum Melting
1. Proper maintenance can ensure good working performance and long service life of the equipment.
2. After the completion of each shift, the equipment shall be dewatered: the method is to dry the water drops with an air gun, and clean the dust and sundries on the working table to ensure that the equipment is clean and tidy
3. Requirements for water cooling: water cooling is extremely important for induction heating equipment. Poor water quality will lead to rust and scaling inside the equipment and pipe blockage, which will directly lead to equipment damage and failure to work properly.
4. It is forbidden to heat the coil without water, otherwise, the coil will burn out and the power supply will burn out due to no load.
5. Recommended cooling water: distilled water - softened water - purified water - filtered tap water
6. Prohibited cooling water: seawater, salt water, unfiltered river water, and well water.
7. Recommended water supply mode: closed circulating water supply+water cooling heat exchanger.
8. Input voltage three-phase 380V (three-phase five-wire power supply).
9. After the machine is powered on, it is forbidden to touch all input and output connectors of the power supply and transformer to avoid safety accidents.
10. When repairing the equipment, the air switch of the equipment and the external main switch must be turned off to stop the water transmission equipment.
11. The equipment shall be protected from exposure to sunlight, rain, and humidity.
12. The maintenance of equipment shall be carried out by professional personnel.
13. Do not turn on the power supply when the control box door is not closed to avoid safety accidents.
14. Turn off the power supply of the control box after the work is completed, and stop the water supply after 15 minutes to avoid damaging the power supply.
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