1 advantages of induction heating
Compared with the flame furnace and electric resistance furnace heating, the main advantage of induction heating:
(1) the heating speed is fast, it can significantly improve the heating equipment productivity, reduce the cost, improve the service life of the die.
(2) the heating time is short, high efficiency. Induction heating furnace equipment productivity is up to 60%~70%, while the flame furnace is only about 20%, only about 40% of the resistance furnace.
(3) induction heating blank oxidation rate is only 0.3%~1%, while the flame furnace burning loss rate is 3%.
(4) the induction heating equipment, less heat dissipation, rarely produce smoke dust, workshop temperature is relatively small, can improve the workshop environment and working conditions.
(5) is convenient for computer operation, easy to realize modern management model.
2 process improvement
Shanxi North Huifeng electromechanical Co., four factory production of an aluminum alloy parts, the original has been using resistance furnace heating way. When in work, the batch of 60 blank into the resistance furnace, heating is about 1H, and then manually piece out, extrusion die in forging machine, to join the second batch of blank resistance furnace heating. The total picking time is about 30min. In the production process, high temperature when baking, workers on the operation of the more serious, and the rough uneven temperature, surface oxidation is more serious, part of rough corners over burning, low productivity.
At present, the induction heating by the State Economic and Trade Commission and the State Environmental Protection Administration included in the "national key industry clean production technology oriented directory (second batch)". In response to the call of the national energy-saving emission reduction, the assets of the company operating the Department of purchasing a set of induction heating equipment, used to replace the existing resistance furnace heating. The four branch in time for the improvement of the heating process.
Power induction heating device power purchase of 50KW, frequency of 2500Hz, into the line voltage is 380V, 50Hz, three-phase five wire system, the intermediate frequency voltage is 700V, the heating temperature of 450 DEG C.
Heating method using artificial pendulum is set up according to material, equipment metronome beat automatic pusher, single heating time is 30s, the blank of burning loss rate is greatly reduced.
Effect of 3
Through the production and application of long-term, medium frequency heating furnace and electric resistance heating furnace are compared, medium frequency heating furnace in the blank heating quality, production efficiency is greatly improved, and the energy saving resistance furnace in the above comparison, energy consumption is reduced by about more than 80%, as described in the following table:
Comparison of production of an aluminum alloy parts required energy consumption:
Heating mode
The actual use of power
Takt time
Production of 10000 energy requirements (kW, H)
(by 1.5 yuan /kw, H)
Resistance furnace
20KW
90s/
7500
Induction heating furnace
10KW
30s/
1249
Heating mode
The actual use of power
Takt time
Production of 10000 pieces of the required energy consumption (kW - H)
(according to 1.5 yuan /kw - H)
Resistance furnace heating 20KW 90s/ 7500
10KW 30s/ induction heating furnace 1249
* the following to the resistance furnace production rhythm calculation: each furnace heated blank 60, heating time of about 1.0h, each furnace blank 0.5h for warm extrusion, the resistance production rhythm is: (1 + 0.5) x 60 / 60min = 1.5min
From the table we can analyze:
(1) by intermediate frequency heating blank through the furnace, compared with the resistance heating furnace can reduce energy consumption 83.3%.
(2) to make use of medium frequency heating furnace, because the heating speed, efficiency and make warm extrusion production can be multiplied many times over.
(3) the use of heating medium frequency heating furnace, uniformity and consistency compared with blank heating resistance furnace heating is greatly improved.
(4) the use of heating medium frequency heating furnace, making the scene environment extrusion procedure is also significantly improved.