Round steel induction heating furnace

Round steel induction heating furnace

Selection method of induction heating furnace for heating forged round bars and bars.

Features

Selection method of induction heating furnace for heating forged round bars and bars.

 

Detailde


Round steel induction heating furnace

The whole set of round steel induction heating furnace equipment is controlled by PLC programmable console. The equipment has a high degree of automation. The heating temperature of the workpiece is measured by an infrared thermometer, and the data is transferred to the PLC . The power supply is automatically adjusted and the heating temperature of the workpiece can be adjusted. Strong control. In addition, the whole set of metal heat treatment equipment can be equipped with automatic feeding, discharging mechanism, closed cooling tower, low-voltage electric cabinet, etc.

Summary table of technical parameters of round steel induction heating furnace

Summary table of technical parameters of round steel induction heating furnace with power less than 1000KW
Rated power (KW )  Rated frequency (HZ)  Transformer capacity (KVA)  Secondary voltage (V)   Rectified pulse number  Inductor voltage (V)  Power consumption (KW.h/t)   Round steel diameter ( mm )
80 1000~8000 100 380v 6 Pulse 800 450 φ 6-35
100 1000~8000 160 380v 6 Pulse 800 450 φ 25-40
120 1000~8000 200 380v 6 Pulse 800 450 φ 30-50
160 1000~8000 250 380v 6 Pulse 800 450 φ 40-60
200 1000~8000 315 380v 6 Pulse 800 450 φ 40-60
250 1000~8000 400 380v 6 Pulse 800 450 φ 60-80
350 1000~8000 500 380v 6 Pulse 800 450 φ 80-120
400 500~8000 500 380v 6 Pulse 800 450 φ 80-120
500 500~8000 630 380v 6 Pulse 800 450 φ 120-150
1000 500~1000 1250 660V-380V 12 Pulse  1200 /(800) 380 φ 150-250
1500 500~1000 1600 φ 660V-380V 12 Pulse  1200 /(800) 370 φ 250-400
2000 500~1000 2200 φ 660V-380V 12 Pulse  1200 /(800) 360 φ 400-800
 

Round steel induction heating furnace application assembly drawing
 Application fields of round steel induction heating furnace:
Forging heating: used for heating round steel, round steel, square steel, steel plate, heating, on-line heating of blue quenching blanking, local heating, on-line forging of metal materials (such as precision forging of gears, semi-shaft connecting rods, bearings, etc.), Extrusion, hot rolling, heating before shearing, spray heating, thermal assembly, and overall heating, annealing, and tempering of metal materials.
Heat treatment: mainly for shafts (straight shafts, variable diameter shafts, camshafts, crankshafts, gear shafts, etc.); gears; sleeves, rings, disks; machine tool screws; guides; planes; ball heads; hardware tools, etc. Surface heat treatment of mechanical (automobile, motorcycle) parts and overall heating, annealing, and tempering of metal materials.
What parameters are required for round steel induction heating furnace selection?
The selection of round steel induction heating furnace 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 material of the workpiece to be heated (generally induction heating, only for metal conductor materials).
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 round steel induction heating furnace can be selected including matching power.
What are the characteristics of the furnace body structure of the round steel induction heating furnace?
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.
How to calculate the power supply of round steel induction heating furnace?
  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.
How to choose the power frequency of round steel induction heating furnace?
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.
How to choose and choose round steel induction heating furnace? Mainly to consider from several aspects:
1. The shape and size of the heated workpiece
  For large workpieces, round steel, and solid materials, round steel induction heating furnaces with relatively high power and low frequency should be used; round steel induction heating furnaces with relatively low power and high frequency should be used for small workpieces, pipes, plates, gears, etc.
2. The depth and area that need to be heated
  The heating depth is deep, the area is large, and the round steel induction heating furnace with high power and low frequency should be used for the overall heating; the heating depth is shallow, the area is small, and the local heating is used, and the round steel induction heating furnace with relatively low power and high frequency should be selected.
3. Required heating rate
  If the heating speed is fast, the round steel induction heating furnace with relatively large power and relatively high frequency should be used.
4. Continuous working hours of equipment
  The continuous working time is long, and the round steel induction heating furnace with slightly larger power is selected.
5. The connection distance between the sensing component and the equipment
  The connection is long, and even water-cooled cable connection is required. Therefore, an induction heating furnace with a relatively large power should be used .
6. Process requirements
  Generally speaking, for processes such as quenching and welding, you can select a lower power and a higher frequency; for annealing and tempering processes, select a higher relative power and a lower frequency; red punching, hot forging, smelting, etc., need If the heating effect is good, the power should be larger and the frequency should be lower.
7. The material of the workpiece
  Among the metal materials, the higher melting point is relatively large, the lower melting point is relatively small; the lower resistivity is higher, and the higher resistivity is lower. ​
Significant advantages of round steel induction heating furnace:
1. Compared with traditional heating methods (oil, coal, gas), it has the obvious advantages of environmental protection, energy saving, convenient operation and low labor intensity;
2. Compared with thyristor intermediate frequency, energy saving is 10%~30%, and there is no harmonic interference to the power grid;
3. Compared with resistance furnace, energy saving is 50%~60%;
4. It has the advantages of fast heating, uniform heating, no oxide layer, and good product quality for customer products;
5. The inductor is isolated by a transformer, which is very safe.
6. Environmental protection: no pollution, noise and dust.
7. Strong adaptability: It can heat various workpieces with different shapes.
8. The equipment occupies a small area, less than two square meters, which is convenient for customers to maximize the use of production space.
Why is the round steel induction heating furnace so efficient?
The principle of the round steel induction heating furnace is electromagnetic induction, and its heat is generated in the workpiece itself. Ordinary workers can use the round steel induction heating furnace to perform continuous forging tasks ten minutes after going to work. The furnace is closed. There is no need to worry about the waste of heated billets in the coal furnace caused by power outages or equipment failures. Because this heating method heats up quickly, there is very little oxidation, and each ton of forgings can save at least 20- of steel raw materials compared with coal-fired furnaces. 50 kg, the material utilization rate can reach 95%. Because this heating method heats evenly and the temperature difference between the core and the surface is very small, the life of the forging die is greatly increased in forging, and the surface roughness of the forging is also less than 50um. The heat 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 the temperature control system can realize the precise control of the temperature and improve the product quality and qualification rate.
 

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