感應(yīng)加熱生產(chǎn)線2020新型

一、設(shè)備用途：

本套設(shè)備可用于φ30～φ120棒料的整體透熱。由于加熱時加熱多種工件，必需使用4種規(guī)格的加熱爐體(GR-30,GR-50.GR-80GR-120)以提高加熱效率，采用單工位加熱方式。設(shè)備的加熱功率經(jīng)計算選為350KW，頻率確定為6000Hz～1000Hz。加熱爐體采用快速更換方式，當(dāng)更換產(chǎn)品規(guī)格時只須更換爐體即可。

工件參數(shù)如下表所示

加熱溫度：1200℃

二、工作過程簡述和供貨范圍:

1、工作過程簡述：

人工從料箱中將料一根根擺放至斜滾板上(可放10--15根料)并排列整齊，坯料依次滑入進料槽后用氣動推料裝置按節(jié)拍將料推進感應(yīng)爐進行加熱，至出料端達到規(guī)定溫度，由滑槽滑入下道工序。

1.供貨范圍見下表

三、制造標(biāo)準(zhǔn)：

1.ZB46001—87《感應(yīng)加熱用半導(dǎo)體變頻裝置》；

2.JB4086—85《中頻感應(yīng)加熱用電控設(shè)備技術(shù)條件》；

3.GB1006.3—88《電熱設(shè)備基本技術(shù)條件.感應(yīng)加熱設(shè)備》；

4.GB5959.3—88《電熱設(shè)備的安全—對感應(yīng)和導(dǎo)電加熱設(shè)備及感應(yīng)

熔煉特殊要求》；

5.GB/5226-1996《工業(yè)機械電氣設(shè)備通用技術(shù)條件》標(biāo)準(zhǔn)。

四、甲方應(yīng)滿足的現(xiàn)場工作條件：

1提供電源：3Ф380V±10%50HZ440KVA

2海拔高度：小于等于1000M

3相對濕度：不大于95%

4冷卻循環(huán)水：Z高進水溫度不高于35℃。0.2-0.3mpa水壓。耗水量15立方米/小時。水質(zhì)應(yīng)軟化。

5無導(dǎo)電塵埃和腐蝕性氣體

6提供壓力為0.4-0.6mpa的氣源

7.甲方應(yīng)按照乙方提供的基礎(chǔ)圖和水路圖進行土建基礎(chǔ)施工和冷卻水源和設(shè)備之間的聯(lián)接。

五、設(shè)備的主要技術(shù)指標(biāo)和特點：

1.晶閘管中頻電源:

1.1功率為350KW、頻率為1000Hz、2500Hz、6000Hz。

1.2啟動成功率可達99%

1.3整流功率因數(shù)大于等于0.92

1.4具有溫度接口可實現(xiàn)溫度閉環(huán)控制

1.5具有內(nèi)外轉(zhuǎn)換及自動手動轉(zhuǎn)換功能

1.6多工位結(jié)構(gòu)可根據(jù)不同被加熱工件方便快捷的更換爐體

1.7中頻電壓750V

1.8直流電壓500V

1.9全數(shù)字，無繼電控制回路，使系統(tǒng)運行穩(wěn)定可靠

1.10具有過流、過壓、欠壓、缺相、水壓、水溫等齊全保護，確保發(fā)生任

何故障均不損壞設(shè)備元器件

1.11三相進線不分相序，可任意連接

1.12操作簡便的“傻瓜"型設(shè)備，決不會發(fā)生誤操做

1.13中頻變頻器柜內(nèi)晶閘管等主要元件及整線主要元件優(yōu)選器

件，所有設(shè)計部件因采購困難需替換時高靠一級，以保證設(shè)備運行穩(wěn)定可靠。

1.14中頻感應(yīng)加熱爐具有保溫功能（中頻電源低功率運行），保溫時間不少于30分。

1.15加熱后各種毛坯達到不同材質(zhì)的工藝溫度（Z高1250℃）,且料間不粘連。

1.16材料燒損率：≤0.6％。

1.17每噸毛坯(典型料)感應(yīng)加熱耗電量：＜380KWh

1.18電路結(jié)構(gòu)：并聯(lián)逆變。

1.19在電網(wǎng)電壓波動10％的情況下，中頻輸出電壓波動不大于±1％。

1.20電抗器采用雙層銅管結(jié)構(gòu)、內(nèi)部各種銅連接截面積足夠大,以減少發(fā)熱。

1.21溫度均勻性：坯料出爐時心表溫差、軸向溫差、上下部溫差≤50℃

2.感應(yīng)加熱器:

2.1感應(yīng)加熱器為快換接頭結(jié)構(gòu)。

2.2感應(yīng)器采用優(yōu)質(zhì)打結(jié)料打結(jié)而成。

2.3感應(yīng)器內(nèi)水冷導(dǎo)軌采用不銹鋼材料制做，表面噴涂一層鈷鎢材料或堆焊不銹鋼焊條保證結(jié)實耐用。各種感應(yīng)器之間接口處設(shè)有滑槽，以利于氧化皮的清理。

2.4感應(yīng)器線圈、匯流排、各連接導(dǎo)線截面積足夠大，以減少發(fā)熱。

2.5感應(yīng)器線圈內(nèi)部連接可靠，感應(yīng)器嚴(yán)格按工藝要求制造,裝配前高壓試漏。

2.6感應(yīng)器線圈上安裝了溫度開關(guān)，水溫超過65℃時自動停機。不工作時，感應(yīng)器線圈內(nèi)的冷凝水可通入壓縮空氣排出

2.8感應(yīng)加熱器的進料端采用氣缸進料機構(gòu)進料，以保證輸送速度均勻一致。

2.9感應(yīng)加熱器為快換互換結(jié)構(gòu)，單節(jié)更換時間不高于10分鐘（感應(yīng)

加熱器單節(jié)可快換互換）;

2.10感應(yīng)器線圈正常使用壽命在3年以上。

2.11感應(yīng)器采用并聯(lián)變匝設(shè)計,坯料由進料至出料端溫度逐漸升高,以保證毛坯在加熱過程中不產(chǎn)生細(xì)微裂紋、超溫過燒等缺陷。感應(yīng)器線圈、匯流排、各連接導(dǎo)線截面積足夠大，以減少發(fā)熱。

2.12感應(yīng)器線圈內(nèi)部連接可靠，感應(yīng)器嚴(yán)格按工藝要求制造,裝配前高壓試漏。

3、中頻諧振電容器

中頻諧振電容器選用新安江電力電容器廠生產(chǎn)的電熱電容器，電爐型號為RFM0.75-1000-1S.RFM0.75-1000-2.5S.RFM0.75-1000-6S

4、操作臺

操作臺面板上安裝有中頻電壓、功率、直流電流的顯示以及中頻電源控制開關(guān)、手動自動旋鈕、功率調(diào)節(jié)旋鈕及急停按鈕，等相關(guān)的操作控制和按鈕開關(guān)。

5.安全措施：

5.1設(shè)備電器連接部位設(shè)有必要的警示（閃電符號、提示語、隔板等）、防護及屏蔽，保護維修、操作者的安全。

5.2整套裝置聯(lián)鎖及保護性能；有緊急停止、過電壓、過電流、缺相、電壓反饋、電流反饋、元件過溫及冷卻系統(tǒng)欠壓斷水、水溫高等聯(lián)鎖、故障報警,保證不使設(shè)備損壞，料化在感應(yīng)加熱器內(nèi)、人身安全等故障發(fā)生。

5.3整套裝置啟、停可靠，時序合理，能有效避免誤操作對設(shè)備及人身造成的危害。

5.4制造及安裝按照機械工業(yè)部<<機械工廠安全性評價標(biāo)準(zhǔn)>>執(zhí)行。

5.5按國家感應(yīng)加熱爐標(biāo)準(zhǔn)制造，符合國家環(huán)保和安全標(biāo)準(zhǔn)。

Bar heat treatment Induction heating production line

First, the use of equipment:

his 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 bodies (GR-30, GR-50.GR-80GR-120) to improve heating efficiency, using single station heating.he heating power of the equipment is calculated to be 350 KW, and the frequency is determined to be 6000 Hz to 1000 Hz..he heating body adopts the quick replacement method, and only the body needs to be replaced when the product specifications are replaced.

he 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. he blanks are sequentially slid into the feed slot and then propelled by the pneumatic push device. he is heated until the discharge end reaches the specified temperature, and the chute slides into the next process.

1. he scope of supply is as follows

hird, the manufacturing standards:

1.ZB46001—87"Semiconductor frequency conversion device for induction heating";

2.JB4086-85"echnical 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.GB5959.3-88 "Safety of electric heating equipment - for induction and conduction heating equipment and induction

Special requirements for smelting;

5.GB/5226-1996 "General technical conditions for industrial machinery and electrical equipment" standard.

four,he on-site working conditions that Party A should meet:

1Power supply: 3Ф380V±10%50HZ440KVA

2Altitude: less than or equal to 1000M

3Relative humidity: no more than 95%

4Cooling circulating water: Z high influent temperature is not higher than 35 C.0.2-0.3mpa water pressure.he water consumption is 15 cubic meters / hour.he water quality should be softened.

5No conductive dust and corrosive gases

6Provide 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,he main technical indicators and features of the equipment:

1.hyristor intermediate frequency power supply:

1.1 power is 350KW,he frequency is 1000 Hz, 2500 Hz, and 6000 Hz.

1.2 startup success rate can reach 99%

1.3Rectification 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

1.6he multi-station structure can easily and quickly replace the 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 pide the phase sequence, can be connected arbitrarily

1.12 easy to operate "fool" type equipment, never misunderstanding

1.he 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 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.

1.16Material 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.he 20 reactors are made of double-layer copper tube structure, and the internal copper cross-sectional area is large enough.o reduce fever.

1.21 emperature 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 he sensor is made of high quality knotted knot.

2.3 he 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.

2.4he inductor coil, the bus bar, and the connecting wires have a large cross-sectional area to reduce heat generation.

2.5he 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 he temperature switch is installed on the sensor coil, and it will stop automatically when the water temperature exceeds 65 ℃.When not working, the condensate in the inductor coil can be discharged through compressed air.

2.8he feed end of the induction heater is fed by a cylinder feed mechanism to ensure uniform delivery speed.

2.9he induction heater is a quick change interchangeable structure, and the single section replacement time is no more than 10 minutes (induction

he heater block can be exchanged quickly;

2.10 he sensor coil has a normal service life of more than 3 years.

2.11he 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.he inductor coil, the bus bar, and the connecting wires have a large cross-sectional area to reduce heat generation.

2.12he 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

he 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

he 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 he 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 standard and meets the national environmental protection and safety standards.

415

427

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