Making spring medium frequency induction heating equipment
A, main process parameters:
The diameter of the heating bar: Φ12~16×3000~6000mm,
Φ22~25×3000~6000mm
Φ32~36×3000~6000mm
Φ40~48×3000~6000mm
Bar temperature heated to: 980 ~ 1100 ° C
Bar processing cycle: general specifications 2 to 4 minutes / each piece, large size can be 5 minutes / each piece
B, equipment power parameter calculation:
According to the characteristics of medium frequency induction heating and the experience in practical applications, such workpieces are generally heated.
It is divided into two stages----first low frequency heating, and then high frequency insulation. Such scientific and rational use of equipment not only ensures the process requirements of the workpiece, but also utilizes energy efficiently and improves production efficiency.
According to the technical parameters of the workpiece heating process and the technical requirements of the heating process, the workpiece is heated and insulated. The warming section is equipped with a dual-band intermediate frequency power supply of the model KGPS-500/4, 8. When heating Φ12~16, Φ22~25, the frequency is 8KHz, the power is used at 250KW; when heating Φ32~36, Φ40~48, the frequency is 4KHz, and the power is used at 500KW. The thermal insulation section is equipped with an intermediate frequency power supply of KGPS-250/8, the frequency is 8KHz, and the power is 250KW.
The heating intermediate frequency power supply is as follows:
Outer diameter dm | Heating temperature °C | Running speed dm/s | Required power kw |
0.12 | 1100 | 0.5 | 56.57652 |
0.16 | 1100 | 0.5 | 100.5805 |
0.22 | 1100 | 0.5 | 190.16 |
0.25 | 1100 | 0.5 | 245.5578 |
0.32 | 1100 | 0.33 | 265.5325 |
0.36 | 1100 | 0.33 | 336.0645 |
0.4 | 1100 | 0.33 | 414.8945 |
0.48 | 1100 | 0.25 | 452.6122 |
0.5 | 1100 | 0.25 | 491.1156 |
It can be seen from the power calculation table that the diameter is in the range of Φ12~25. When the medium frequency power supply of KGPS-250/8.0 is used to heat to 1100 °C, the beat can reach 2 minutes per piece; the diameter is in the range of Φ32~50, using KGPS. When the medium frequency power supply of -500/4.0 is heated to 1100 °C, the Φ32~40 specification can achieve a beat of /3 minutes per piece, and the Φ48~50 specification can reach 1/4 beat per piece.
Therefore, the intermediate frequency power supply with the temperature rise configuration can not only meet the requirements of the heating process, but also can meet the maximum production efficiency.
C , equipment system configuration
1. Electrical parts:
KGPS-500/4~8 medium frequency power supply
KGPS-250/8 medium frequency power supply
Capacitor cabinet: 500KW/4, 8KHz dual frequency
Capacitor cabinet: 250KW/8KHz
Heating sensor: GTR25×500 (heating φ12～16, each set of 3)
Heating sensor: GTR35×500 (heating φ22～25, each set of 3)
Heating sensor: GTR50×500 (heating φ32～36, each set of 3)
Heating sensor: GTR60×500 (heating φ40～48, 3 sets each)
Insulation sensor: set of GTR25×500 (heating φ12～16, each set of 9)
Insulation sensor: GTR35×500 (heating φ22～25, 9 sets per set)
Insulation sensor: set of GTR50×500 (heating φ32～36, 9 sets each)
Insulation sensor: GTR60×500 (heating φ40～48, 9 sets per set)
Operator station: dedicated one
Rectifier transformer: 1000KVA
Infrared Thermometer: A set of American Leitai TX
Programmable controller: a set of Siemens S7-200
Computer and software, printer
2. Mechanical part
Workpiece heating transmission system (including inverter, motor, reducer, chain, etc.)
set
Rapid workpiece discharge device (including inverter, motor, reducer, chain, etc.)
set
Feed drive shaft assembly
In-sensor drive shaft assembly
Discharge drive shaft assembly
Rack
Quick lift wheel set assembly
3. Spare parts
Main control panel DH-4A set
Fast-acting fuse 1000A/500V three
Rectifier thyristor KP1000A/1200V three
Rectifier thyristor KP500A/1200V three
Inverter thyristor KA500A/900V double string two sets
Inverter thyristor KA1000A/900V double string two sets
Inverter RC absorption 8Ω/0.1μ four sets