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Induction heating features:
(1) The heating temperature is high and it is non-contact heating.
(2) High heating efficiency.
(3) The heating rate is fast.
(4) The temperature is easy to control.
(5) Local heating is possible; (6) Automatic control is easy.
(7) The working environment is good and there is almost no noise or dust.
(8) The work covers less land and the production efficiency is high.
(9) It can heat workpieces with complex shapes.
(10) The workpiece is easy to heat evenly and the product quality is good.
(11) The solution has electromagnetic stirring during smelting. The composition of the molten metal can be uniformly adjusted, the temperature of the solution is uniform, and local high temperature does not occur. Less metal burnout is more important for smelting rare metals.
Advantages of induction heating: First, low energy consumption. The actual billet heating efficiency of the induction melting furnace and the induction diathermy furnace can reach 65% to 75%, while the flame furnace and various chamber furnaces are only about 30%.
Secondly, this type of furnace does not require the necessary preheating process such as coal stove, gas stove and electric resistance furnace. It is easy to use and easy to operate. It can work continuously for a long time or can be started or stopped at any time according to needs. Full manual or fully automatic Or semi-automatic work, you can have an absolute advantage in production scheduling.
Thirdly, there is no need to heat the whole workpiece, local heating can be selected, so the electric energy consumption is small, the deformation of the workpiece is small and the heating speed is fast, so that the workpiece can reach the required temperature in a very short time, so that the surface of the workpiece is oxidized and decarburized. When the heating defects are reduced to a low level, it can be used for steel materials such as steel, tungsten, molybdenum, etc. It can also be applied to the heating or heat treatment of aluminum, titanium, zirconium and hafnium which are more chemically active.
Fourth, the induction heating equipment can be installed on the production line, which is easy to realize the automation and mechanization of the production line, and is easy to manage, which can effectively reduce transportation, save manpower and improve production efficiency.
Fifth, induction heating also has the advantages of high power utilization, environmental protection, energy saving, safety and reliability, and a good working environment.
Based on the above advantages, in the replacement of coal, oil, gas and other non-renewable energy in the heating field is gradually becoming a dominant energy source, induction heating is increasingly used in the fields of melting, heating, etc., electric heating, especially induction heating applications have Very broad application prospects, induction heating equipment manufacturers have a broad space for development.
Application in automobile manufacturing
The booming automotive industry has brought unprecedented opportunities for the automotive parts industry. Induction heating technology is also being used more and more widely in the field of automobile manufacturing.
In terms of smelting, casting is an easy-to-form metal processing method. Casting methods can be used to make parts of various sizes and complex shapes in automobiles. It can be said that the development of the automotive industry is making the best use of it, and almost all casting processes can do their best in the automotive industry. The smelting processes mainly used in the production of foundry auto parts at home and abroad include cupola smelting process, medium frequency induction furnace smelting process and cupola-medium frequency induction furnace double smelting process, while induction smelting furnace is also getting in the foundry industry due to its technical advantages. An increasingly wide range of applications.
In terms of heating, according to statistics, the parts of the former Soviet Union that inductively heat-treated in the automotive industry accounted for 40% to 45% of heat-treated parts. The development of induction heating technology to today, its application and development level is self-evident.
Induction heating technology is mainly used in the automotive industry in the following areas:
(1) Melting of metals.
(2) Heating of the forged blank.
(3) Heat treatment of automotive parts.
(4) Induction heating curing after bonding of automotive parts.
(5) Induction heating semi-solid forming.
(6) Induction heating assembly.
(7) Induction heating brazing.
Status of induction heating abroad
With the development of power semiconductor devices and the continuous development of power electronics technology, the appearance of induction heating devices has also changed with each passing day, especially in terms of volume, quality and performance. For example, the frequency, the same-capacity transistor-type inverter device is 2/3 smaller than the tube-type inverter device, the weight is reduced by 2/3, the cooling water is saved by 1/2, the power consumption is saved by 1/3, and the efficiency is increased by 35%. Longer service life, safer and more reliable, easy to achieve automatic control, is conducive to improve heating efficiency and quality, maintenance workload is smaller, can be used with the use.
The technological development and application of induction heating devices in industrialized countries such as Germany, the United States, the United Kingdom, France, Japan, Italy, Spain, Belgium and Russia are among the world's foremost.
Domestic development and current situation
The application of induction heating technology in China began in the 1950s. The development was mainly after the reform and opening up, mainly used in the manufacturing of machine tools, automobiles, tractors and so on. Induction heating concentrates on the surface quenching of the workpiece, while smelting and diathering applications are less. The technology of induction heating is almost entirely from the former Soviet Union and the Czech Republic. In the 1980s, Zhejiang University independently developed the first parallel thyristor intermediate frequency power supply and promoted it nationwide.
In the 1990s, some foreign induction furnace companies went directly to China to set up factories, such as the United States Inductive Heating Company and the company, and competed with domestic manufacturers in the same industry. Their products have high technical content, large power supply, full brand, large tonnage of furnaces and large scale of production lines, occupying a large part of the domestic market. Only their equipment prices are high (domestic performance products are about 1/5 of their price), which makes domestic manufacturers have a certain market development space.
Domestic induction heating is also geographically divided into “Southern†and “Northern†technologies and products. The representatives of “Nanpai†include Zhenwu, Sida, Zhaoli and other companies; “North School†is represented by Xi'an induction heating company. Xi'an Boda Electric Furnace Co., Ltd. and Xi’an Electric Furnace Research are among the most influential among these manufacturers. Ltd., Xi'an Pengyuan Heavy Electric Furnace Factory, Xi'an Electromechanical Research Institute, Shaanxi Haiyi, Xi'an Automation and Huali.
Induction heating device development trend
The induction heating device consists of two parts, one is the AC power supply that provides energy, also called the variable frequency power supply, and the other is the induction coil and mechanical structure that completes the electromagnetic induction energy conversion, called the induction furnace. The variable frequency power supply has the division of power frequency, intermediate frequency and high frequency.
(1) High-frequency heating equipment It has a set of equipment that converts the power frequency 50Hz alternating current into high-frequency (70 000~1 000 000 Hz) electric energy, usually using a tube high-frequency generator.
(2) Intermediate frequency heating equipment There is also a set of equipment that converts the power frequency 50Hz into an intermediate frequency (500~10 000Hz), usually an intermediate frequency generator (low power factor) and a thyristor inverter.
(3) Power frequency induction heating device The power frequency of the sensor is the same as the frequency of the power grid, that is, 50 Hz, so energy can be directly extracted from the power grid. The fly in the ointment is that the power factor is too low.
With the development of market demand, the development of induction heating devices has become high-frequency with the increase of the capacity of power electronic power devices. The control simulation of electronic technology devices has become digital, automatic control and intelligent development, and the development of induction heating devices The trend presents the following characteristics:
(1) Power supply tends to high frequency and large capacity The main frequency band of induction heating power supply adopts thyristor; the super audio section mainly adopts IGBT; the high frequency frequency band is originally SIT, and now mainly develops MOSFET power supply. Power supplies using IGCT are also beginning to debut. The need for high-frequency power supplies has spawned new power devices, which in turn have contributed to the development of high-frequency power supplies. The large capacity of induction heating power supplies, such as tens of megawatts and hundreds of megawatts, can be achieved.
(2) Induction heating devices tend to be mechanized and automated In recent years, with the rapid development of mechatronics, computers, information and control, equipment automation, new materials, new processes, etc., casting, forging and heat treatment processes tend to be digital and precise. . Reflected in the demand for heating is: digital manufacturing into the casting and forging process, including heating, smelting equipment; casting and forging short process production requires reducing waste of resources; large casting and forging production requires industrial energy saving; clean production under automated control.
Therefore, under the characteristics of energy saving and environmental protection, induction heating equipment has a tendency to develop toward large-scale, automation and control in the direction of intelligence.
Application and development of induction heating technology
As an emerging discipline, induction heating has been used in the past 30 years. In today's energy shortage, its importance is particularly prominent, and technology is rapidly increasing and its use is becoming more widespread. China began to develop induction heating technology after the reform and opening up, and its application prospects are very promising.