感应加热生产线2020新型

一、设备用途：

本套设备主要用于φ30～φ120棒料的整体透热。由于加热时加热多种工件，必需使用4种规格的加热炉体(GTR-30,GTR-50. GTR-80 GTR-120)以提高加热效率，采用单工位加热方式。设备的加热功率经计算选为350KW，频率确定为6000Hz～1000Hz 。加热炉体采用快速更换方式，当更换产品规格时只须更换炉体即可。

工件参数如下表所示

加热温度：1200℃

二、 工作过程简述和供货范围:

  1、工作过程简述：

人工从料箱中将料一根根摆放至斜滚板上(可放10--15根料)并排列整齐，坯料依次滑入进料槽后用气动推料装置按节拍将料推进感应炉进行加热，至出料端达到规定温度，由滑槽滑入下道工序。

1.供货范围见下表

三、制造标准：

1. ZB46001—87 《感应加热用半导体变频装置》；

2. JB4086—85  《中频感应加热用电控设备技术条件》；

3. GB1006.3—88《电热设备基本技术条件.感应加热设备》；

4. GB595 9.3—88《电热设备的安全—对感应和导电加热设备及感应

熔炼特殊要求》；

5. GB/T5226-1996《工业机械电气设备通用技术条件》标准。

四、 甲方应满足的现场工作条件：

1 提供电源：3Ф 380V±10%  50HZ 440KVA

2 海拔高度：小于等于1000M

3 相对湿度：不大于95%

4 冷却循环水：Z高进水温度不高于35℃ 。 0.2-0.3mpa水压。耗水量15立方米/小时。水质应软化。

5 无导电尘埃和腐蚀性气体

6 提供压力为0.4-0.6mpa的气源

7.甲方应按照乙方提供的基础图和水路图进行土建基础施工和冷却水源和设备之间的联接。

五、 设备的主要技术指标和特点：

1. 晶闸管中频电源: 

1.1功率为350KW、 频率为1000Hz、2500Hz、6000Hz。

1.2启动成功率可达100%

1.3 整流功率因数大于等于0.92

1.4具有温度接口可实现温度闭环控制

1.5具有内外转换及自动手动转换功能

1.6 多工位结构可根据不同被加热工件方便快捷的更换炉体 

1.7中频电压750V 

1.8直流电压500V 

1.9全数字，无继电控制回路，使系统运行稳定可靠

1. 10具有过流、过压、欠压、缺相、水压、水温等齐全保护，确保发生任

何故障均不损坏设备元器件

1.11三相进线不分相序，可任意连接

1. 12操作简便的“傻瓜”型设备，决不会发生误操做

1. 13中频变频器柜内晶闸管等主要元件及整线主要元件优选国内先进器

件，所有设计部件因采购困难需替换时高靠一级，以保证设备运行稳定可靠。

1.14中频感应加热炉具有保温功能（中频电源低功率运行），保温时间不少于30分。

1.15加热后各种毛坯达到不同材质的工艺温度（Z高1250°C）,且料间不粘连。

1.16 材料烧损率：≤ 0.6％。

1.17每吨毛坯(典型料)感应加热耗电量：＜380KWh

1.18电路结构：并联逆变。

1.19在电网电压波动10％的情况下，中频输出电压波动不大于±1％。

1. 20电抗器采用双层铜管结构、内部各种铜连接截面积足够大, 以减少发热。

1.21温度均匀性：坯料出炉时心表温差、轴向温差、上下部温差≤50°C

2. 感应加热器:

2.1感应加热器为快换接头结构。

2.2感应器采用优质打结料打结而成。 

2.3感应器内水冷导轨采用不锈钢材料制做，表面喷涂一层钴钨材料或堆焊不锈钢焊条保证结实耐用。各种感应器之间接口处设有滑槽，以利于氧化皮的清理。

2.4 感应器线圈、汇流排、各连接导线截面积足够大，以减少发热。

2.5 感应器线圈内部连接可靠，感应器严格按工艺要求制造, 装配前高压试漏。

2.6感应器线圈上安装了温度开关，水温超过65℃时自动停机。不工作时，感应器线圈内的冷凝水可通入压缩空气排出 

2.8 感应加热器的进料端采用气缸进料机构进料，以保证输送速度均匀一致。

2.9 感应加热器为快换互换结构，单节更换时间不高于10分钟（感应

加热器单节可快换互换）; 

2.10感应器线圈正常使用寿命在3年以上。

2.11 感应器采用并联变匝设计,坯料由进料至出料端温度逐渐升高, 以保证毛坯在加热过程中不产生细微裂纹、超温过烧等缺陷。感应器线圈、汇流排、各连接导线截面积足够大，以减少发热。

2.12 感应器线圈内部连接可靠，感应器严格按工艺要求制造, 装配前高压试漏。

3、中频谐振电容器

中频谐振电容器选用新安江电力电容器厂生产的电热电容器，型号为RFM0.75-1000-1S.   RFM0.75-1000-2.5S.   RFM0.75-1000-6S

4、操作台

操作台面板上安装有中频电压、功率、直流电流的显示以及中频电源控制开关、手动自动旋钮、功率调节旋钮及急停按钮，等相关的操作控制和按钮开关。

5. 安全措施：

5.1设备电器连接部位设有必要的警示（闪电符号、提示语、隔板等）、防护及屏蔽，保护维修、操作者的安全。

5.2整套装置联锁及保护性能；有紧急停止、过电压、过电流、缺相、电压反馈、电流反馈、元件过温及冷却系统欠压断水、水温高等联锁、故障报警,保证不使设备损坏，料化在感应加热器内、人身安全等故障发生。

5.3整套装置启、停可靠，时序合理，能有效避免误操作对设备及人身造成的危害。

5.4制造及安装按照机械工业部〈〈机械工厂安全性评价标准〉〉执行。

5.5按国家感应加热炉标准制造，符合国家环保和安全标准。

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.

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