Bar heat treatment Induction heating production line

First, the use of equipment:

This set of equipment is mainly used for the overall heat transfer of φ30～φ120 bars. Due to the heating of a variety of workpieces during heating, it is necessary to use four types of heating furnace bodies (GTR-30, GTR-50.  GTR-80   GTR-120) to improve heating efficiency, using single station heating. The heating power of the equipment is calculated to be 350 KW, and the frequency is determined to be 6000 Hz to 1000 Hz.   . The heating furnace body adopts the quick replacement method, and only the furnace body needs to be replaced when the product specifications are replaced.

The workpiece parameters are shown in the following table.

Heating temperature: 1200 ° C

two,   Brief description of the work process and scope of supply:

   1. Brief description of the work process:

Manually place the roots of the material from the bin onto the inclined plate (10-15 pieces) and arrange them neatly. The blanks are sequentially slid into the feed slot and then propelled by the pneumatic push device. The furnace is heated until the discharge end reaches the specified temperature, and the chute slides into the next process.

1. The scope of supply is as follows

Third, the manufacturing standards:

1.   ZB46001—87   "Semiconductor frequency conversion device for induction heating";

2.   JB4086-85    "Technical conditions for electronic control equipment for medium frequency induction heating";

3.   GB1006.3-88 "Basic technical conditions of electric heating equipment. Induction heating equipment";

4.   GB595   9.3-88 "Safety of electric heating equipment - for induction and conduction heating equipment and induction

Special requirements for smelting;

5.   GB/T5226-1996 "General technical conditions for industrial machinery and electrical equipment" standard.

four,   The on-site working conditions that Party A should meet:

1   Power supply: 3Ф   380V±10%    50HZ   440KVA

2   Altitude: less than or equal to 1000M

3   Relative humidity: no more than 95%

4   Cooling circulating water: Z high influent temperature is not higher than 35  C  .  0.2-0.3mpa water pressure. The water consumption is 15 cubic meters / hour. The water quality should be softened.

5   No conductive dust and corrosive gases

6   Provide a gas source with a pressure of 0.4-0.6mpa

7. Party A shall carry out the connection between the civil construction and the cooling water source and equipment in accordance with the basic map and waterway map provided by Party B.

Fives,   The main technical indicators and features of the equipment:

1.   Thyristor intermediate frequency power supply:  

1.1 power is 350KW,   The frequency is 1000 Hz, 2500 Hz, and 6000 Hz.

1.2 startup success rate can reach 100%

1.3   Rectification power factor is greater than or equal to 0.92

1.4 with temperature interface for temperature closed loop control

1.5 with internal and external conversion and automatic manual conversion

1.6   The multi-station structure can easily and quickly replace the furnace body according to different heated workpieces.  

1.7 IF voltage 750V  

1.8 DC voltage 500V  

1.9 all digital, no relay control loop, making the system stable and reliable

1.   10 has over-current, over-pressure, under-pressure, phase loss, water pressure, water temperature and other complete protection to ensure the occurrence of any

No faults damage the equipment components

1.11 three-phase incoming line does not divide the phase sequence, can be connected arbitrarily

1.   12 easy to operate "fool" type equipment, never misunderstanding

1.   The main components such as the thyristor in the IF inverter cabinet and the main components of the whole line are preferably domestic advanced devices.

All the design parts need to be replaced by one level due to the difficulty of purchasing, so as to ensure the stable and reliable operation of the equipment.

1.14 medium frequency induction heating furnace has heat preservation function (low frequency operation of medium frequency power supply), and the holding time is not less than 30 minutes.

1.15 After heating, the various blanks reach the process temperature of different materials (Z height 1250 ° C), and the materials do not stick together.

1.16   Material burning rate: ≤   0.6%.

1.17 Induction heating power consumption per ton of blank (typical material): <380KWh

1.18 circuit structure: parallel inverter.

1.19 In the case of grid voltage fluctuations of 10%, the IF output voltage fluctuation is not more than ±1%.

1.   The 20 reactors are made of double-layer copper tube structure, and the internal copper cross-sectional area is large enough.   To reduce fever.

1.21 Temperature uniformity: temperature difference between the surface of the billet when the billet is discharged, axial temperature difference, temperature difference between the upper and lower parts ≤ 50 ° C

2.   Induction heater:

2.1 Induction heater is a quick-change joint structure.

2.2 The sensor is made of high quality knotted knot.  

2.3 The water-cooled guide rail in the sensor is made of stainless steel, and a layer of cobalt-tungsten material or surfacing stainless steel electrode is sprayed on the surface to ensure durability. A chute is provided at the interface between the various sensors to facilitate the cleaning of the scale.

2.4   The inductor coil, the bus bar, and the connecting wires have a large cross-sectional area to reduce heat generation.

2.5   The internal connection of the inductor coil is reliable, and the inductor is manufactured strictly according to the process requirements.   High pressure leak test before assembly.

2.6 The temperature switch is installed on the sensor coil, and it will stop automatically when the water temperature exceeds 65 °C. When not working, the condensate in the inductor coil can be discharged through compressed air.  

2.8   The feed end of the induction heater is fed by a cylinder feed mechanism to ensure uniform delivery speed.

2.9   The induction heater is a quick change interchangeable structure, and the single section replacement time is no more than 10 minutes (induction

The heater block can be exchanged quickly;  

2.10 The sensor coil has a normal service life of more than 3 years.

2.11   The inductor adopts a parallel variable boring design, and the billet gradually increases in temperature from the feed to the discharge end.   In order to ensure that the blank does not produce defects such as fine cracks, over-temperature and over-burning during heating. The inductor coil, the bus bar, and the connecting wires have a large cross-sectional area to reduce heat generation.

2.12   The internal connection of the inductor coil is reliable, and the inductor is manufactured strictly according to the process requirements.   High pressure leak test before assembly.

3. Intermediate frequency resonant capacitor

The intermediate frequency resonant capacitor is selected from the electric heating capacitor produced by Xinanjiang Power Capacitor Factory, the model is RFM0.75-1000-1S.     RFM0.75-1000-2.5S.     RFM0.75-1000-6S

4, the console

The display panel is equipped with a display of intermediate frequency voltage, power, DC current, and an intermediate frequency power control switch, manual automatic knob, power adjustment knob and emergency stop button, and other related operation controls and push button switches.

5.   Safety measures:

5.1 Equipment electrical connection parts are equipped with necessary warnings (lightning symbols, warnings, partitions, etc.), protection and shielding to protect the maintenance and operator safety.

5.2 Interlocking and protection performance of the whole set of equipment; there are emergency stop, over voltage, over current, phase loss, voltage feedback, current feedback, component over temperature and cooling system under pressure and water cut, high water temperature interlocking, fault alarm, guarantee not to make equipment Damage, materialization in the induction heater, personal safety and other failures occur.

5.3 The whole set of equipment is reliable in starting and stopping, and the timing is reasonable, which can effectively avoid the harm caused to the equipment and the human body by misoperation.

5.4 Manufacturing and installation shall be carried out in accordance with the Machinery Industry Safety Evaluation Standards of the Ministry of Machinery Industry.

5.5 It is manufactured according to the national induction heating furnace standard and meets the national environmental protection and safety standards.