Induction heater

Our company has mature design and production experience in the field of induction heater heating, and has provided stable and efficient products for many enterprises. The heating furnace body adopts a quick replacement method, and only the furnace body needs to be replaced when the product specifications are changed. It only takes a few minutes to replace the furnace body. All the water inlet and outlet pipes of the equipment are made of stainless steel, and the pipes are designed for permanent anti-corrosion and rust prevention. The equipment is a power-saving product, which has the characteristics of fast temperature increase, energy saving and consumption reduction, stable and reliable operation ( 24 hours continuous trouble-free operation). The service life of the complete set of equipment is designed and manufactured to be no less than 20 years, and the equipment control technology is in the leading position in the same industry within five years.

1. Composition and configuration of induction heater :

Induction heaters are generally composed of intermediate frequency power supply, electric heating capacitor, induction furnace body, feeding and discharging transmission devices, and temperature measurement equipment. When fully automatic control, it also includes PLC programmable controller, man-machine interface or industrial control computer system, industrial control configuration software and various sensors.

2. Selection parameter table of induction heaters with power within 2000 KW

3. What parameters are required for induction heater selection ?

The selection of induction heater generally requires the following parameters:

First: the shape of the workpiece to be heated, the outer dimensions, and the weight of the workpiece to be heated.

Second: the heated material of the workpiece material (typically induction heating, only for the metal conductor material ).

Third: the time required for the heating of the heated workpiece to the target temperature, and the target temperature.

Once the above three points are clear, the induction heater can be selected including matching power.

Fourth, what are the characteristics of the induction heater furnace body structure?

1. Furnace structure: The heating furnace of our company is designed as an integral quick-change type. When the furnace body is changed for different heating workpieces, rapid replacement can be realized.

2. Furnace lining : The furnace lining adopts silicon carbide or integral knotting method, and the service temperature is above 1450℃ .

3. Protection : automatic shutdown when the water temperature exceeds 65℃ .

4. Induction furnace water-cooled track: A water-cooled track is installed on the lining of the induction furnace.

5. How to calculate the power of induction heater ?

P=(0.168×200×693)/(0.24×0.6×145)=1029KW where: 0.168—average specific heat of ferrous metal; 2080—workpiece mass (Kg); 200—workpiece heating temperature rise; 0.24— Work-heat equivalent; 0.6—average efficiency (in this example, 0.6, generally 0.5～0.65, and special-shaped sensors are lower, 0.4); 145—working cycle (seconds)

Based on the above calculations, 1KHz induction heating equipment with a rated power of 1500KW can be configured to meet the needs.

6. How to choose the power frequency of induction heater ?

The selection of power frequency follows the principle of optimal heating efficiency and temperature uniformity (core-surface temperature difference). The higher the frequency, the higher the heating efficiency, but too high a frequency is likely to cause the surface of the workpiece to burn. According to our experience, select the frequency 2500KHZ , Can get the best heating effect, and will not cause the workpiece temperature to overheat .

Seven, what are the advantages of induction heaters ?

Induction heater induction heating using the conventional flame forged forging process has obvious advantages compared:

1. The heating speed is fast, and the required temperature can be reached in a very short time, which greatly reduces the oxidation of metal, has high production efficiency, less oxidation and decarburization, and saves material and forging die costs.

Since the principle of intermediate frequency induction heating is electromagnetic induction, the heat is generated in the workpiece itself. Ordinary workers can perform continuous forging tasks ten minutes after going to work with the intermediate frequency electric furnace, without the need for professional furnace firing workers to perform furnace firing and sealing work in advance . There is no need to worry about the waste of heated billets in the coal furnace caused by power outages or equipment failures. Due to the fast heating speed of this heating method, there is very little oxidation. Compared with the coal-fired furnace, each ton of forgings can save at least 20-50 kilograms of steel raw materials , and the material utilization rate can reach 95% . Because this heating method heats evenly and the temperature difference between the core and the surface is extremely small, the life of the forging die is greatly increased in forging, and the surface roughness of the forging is also less than 50um .

2. Superior working environment, improved labor environment for workers, no pollution, low energy consumption.

Compared with coal stoves, induction heating furnaces do not produce exhaust gas and smoke such as carbon monoxide, carbon dioxide, sulfur oxides, etc., have low external heat and low noise. Workers will no longer be exposed to the baking and smoke of coal stoves under the scorching sun. The environment is purified and the health level is guaranteed. Induction heating is the most energy-saving heating method in electric heating furnaces. The power consumption of forgings per ton from room temperature to 1100°C is less than 360 degrees.

3. The heating is uniform, the temperature difference between the core and the surface is extremely small, and the temperature control accuracy is high.

The heat of induction heating is generated in the workpiece itself, so the heating is uniform, and the temperature difference between the core and the surface is extremely small. The application of temperature control system can achieve precise control of temperature and improve product quality and qualification rate.

The main equipment of the intermediate frequency heating forging and heat treatment workshop, the stability, reliability and safety of its work are the guarantee for the normal and stable operation of the forging and heat treatment production line of the flow-through operation.

4. It is convenient to replace the furnace body to meet the different requirements of the overall heating of the bar or the heating of the end.

5. It is very convenient to install, debug and operate, and you will know it as soon as you learn;

6. Ultra-small size, movable, convenient to use with any equipment;

IF heating furnace heating apparatus with a small size, light weight, high efficiency, excellent quality and favorable thermal processing environment, etc. are rapidly eliminated coal-fired furnace, gas furnace, oil furnace and general resistance furnace, a new generation of metal heating apparatus.

7. Power saving and environmental protection, heating more evenly and faster, automatic feeding, greatly saving costs;

8. Induction heating does not produce open flames, prevents the possibility of dangerous events such as fires and explosions, and greatly improves safety.

Eight, the purpose of induction heater :

Induction heaters are mainly used for the heating of metal materials before forging, extrusion, hot rolling, and shearing, as well as the overall heat treatment of metal materials such as tempering, annealing, tempering, metal heating forging, extrusion molding, and solder welding.

Common metal plus frequency induction thermal process typical temperature

9. What are the precautions when operating the induction heater ?

1. Before starting the furnace, check whether the electrical equipment, water cooling system, copper tube of the inductor, etc. are in good condition, otherwise it is forbidden to open the furnace.

2. The furnace melting loss exceeding the regulations should be repaired in time. It is strictly forbidden to smelt in a crucible that is too deep.

3. Special personnel should be responsible for power supply and furnace opening. It is strictly forbidden to touch the sensors and cables after power supply. Those on duty are not allowed to leave their posts without authorization, and pay attention to the external conditions of the sensor and the crucible.

4. When charging, check whether there are flammable and explosive materials mixed in the charge. If any, it should be removed in time. It is strictly forbidden to directly add cold and wet materials into the molten steel. After the molten liquid is filled to the upper part, it is strictly prohibited to add bulk , To prevent the cover.

5. It is strictly forbidden to mix iron filings and iron oxide when repairing the furnace and ramming the crucible, and the ramming crucible must be dense.

6. The pouring site and the pit in front of the furnace should be free of obstacles and no water to prevent the molten steel from falling to the ground and exploding.

7. The molten steel is not allowed to be overfilled. When pouring the ladle with hands, the two should cooperate and walk smoothly. No emergency stop is allowed. After pouring, the remaining steel should be poured into the designated place.

8 , induction heater inside should be kept clean, non-inflammable and explosive materials and other debris into the room, no smoking.

10. What are the requirements for the installation of induction heaters

The user needs to provide the site map and some requirements or technical parameters of the site first, and our company will design the detailed site installation layout; 2. The requirements of the equipment on the foundation: flat cement floor, no need to fix or slightly fix

3. The equipment should be placed as far as possible in a ventilated, sunny, and cool outdoor;

4. The user is responsible for the equipment installation materials, required civil engineering and necessary tools. We come to the site to guide the installation and commissioning, and conduct on-site operation training.

5. If the user has special requirements, it can be negotiated by the supplier and the buyer when ordering.

6. The bar requirements , the diameter of 20 or more bar using an induction heater : induction heating bar, heating rods along the surface of the material, the higher the frequency, the shallower the depth of heating, the lower the frequency, the deeper the depth of heating ; such as using when the heating device super audio frequency of about 50KHZ about, heating depth bar is 2-3MM , core bar portion is required on the heat conduction surface of the heating past ; if larger diameter bar, the bar core temperature portion is It is difficult to improve, and there is a large temperature difference with the surface ; this problem can be solved by heating with intermediate frequency. The frequency of the intermediate frequency is 1KHZ-20KHZ , and the appropriate frequency is selected according to the diameter of the heated bar, which can ensure uniform heating from the surface to the core of the bar ;