Induction furnace. Induction heater. Inductor

PURPOSE

The manufactured models of induction furnaces or induction heaters of IH type allow to heat billets with the diameter from 10 to 150 mm. The utilized current frequency ranges from 500 to 10000 Hz. The power ranges from 50 to 1500 kW.
Induction heaters are produced in the form of automated lines with a programmable control system.
Induction furnaces of induction heaters are equipped with:

• A versatile feeding device;
• A system of feeding the billets into the inductor;
• A protection system against billet welding;
• A system of controlling the heating temperature;
• A system of controlling heating time;
• A thermostating system;
• A system of protecting the inductor coils against overheating;
• Malfunction protection system for functioning without the operator;
• A system of maintaining constant voltage.

Induction furnaces or induction heaters are manufactured according to Customer’s requirements specification.

TECHNICAL FEATURES OF BASIC MODELS

LAYOUT OF AN INDUCTION FURNACE

The layout of an induction furnace (induction heater) and the delivery set can be changed based on customer’s demand. The basic delivery set includes:

• Thyristor frequency converter, per customer’s choice
• Electric cabinet
• Inductor
• Control system

Extra delivery:

• Step-by-step feeding device for billet feeding
• Pyrometer
• 3-position manipulator (for differentiate between under heated, normally heated, and overheated billets and feeding the billets into a rolling machine)
• Device for billet smooth pushing into the inductor

LAYOUT OF A COMPLETE SET OF AN INDUCTION FURNACE

TECHNICAL DESCRIPTION OF A BASIC MODEL OF AN INDUCTION FURNACE OR AN INDUCTION HEATER

A basic heater model includes thyristor frequency converter 1, which is connected with the induction heater’s cabinet 2. There are capacitor banks, busway, water supply system, and a system for controlling the water supply installed inside the cabinet. Removable inductor 3 is placed on cabinet 2. As a rule inductor 3 is a pass-through one with water cooled guides. Inductor coils are protected with ceramic sleeves or special concrete. Mechanism 4 for pushing the billets into the inductor is placed at the inductor inlet. Roller system 5 for unloading the heated billets is placed at the inductor outlet.

Thyristor converter 1, pushing mechanism 4 and roller unloading system are connected with control system 6 that allows to feed the billets in set intervals.

Additionally to the basic model an induction heater may include:
- versatile automatic bunker for feeding billets – 7
- chain transporter for creation of billet stock – 8
- mechanism for presorting the billets according to the temperature – 9
- pyrometer – 10
- heat exchanger for a closed loop of distilled cooling water – 11
- control cabinet with a programmable controller to work according to a program – 12
- a system of sensors that control:

• water consumption
• water temperature
• water pressure
• air pressure
• the temperature of each inductor coil
• availability of billets on the transporter
• heating temperature of each billet.

The control system operates according to a program without the presence of a man. The control system ensures:
- accumulation of billets before the inductor
- feeding of billets into the inductor in a set rate
- regulation of the heating temperature in a set range
- heater shutdown in the following cases:

• water supply termination
• insufficient water pressure
• insufficient water consumption
• overheating of the copper shell of each of the coils
• insufficient air pressure
• termination of feeding billets into the inductor