The induction furnace consists basically of a crucible, inductor coil, and shell, cooling system and tilting mechanism. It has an electic inductor coil which has number of turns which have direct contact with the. These considerations, together with furnace users economically motivated demands for a maximum service life of the ceramic furnace lining, call for a technology which permits a visual inspection of the gap between the ceramic furnace lining and the induction coil. A coil, suitably dimensioned, placed close to the metal parts to be heated, conducting high or medium frequency alternated current, induces on the work piece currents eddy currents whose intensity can be controlled and modulated. Coatings for furnace linings, troughs, burners and molds molten aluminum splash protection trough coatings and linings for molten aluminum transfer high temperature patching and sealing of refractory linings lightweight refractory linings induction furnace coil coating high temperature binder and fillers. Long life coil via water cooled magnetic yokes winding coil high durability lining with extra water cooled turns completing bottom and top turns. Inter national journal of engineering and technology vol. This coil type has a number of turns and can be wound from wire or water cooled tubing depending on the application. The furnace coil makes use of ec grade copper tube during its make, while permali is used for the making of the coil support.
The other coil, the secondary winding, s typically consists of up to a million turns of fine wire up to 40 gauge. Features of induction furnace an electric induction furnace requires an. How to make an induction heater like a professional one. Design analysis of an electric induction furnace for melting. Designers tend to avoid use of additional coil components for magnetic flux control in order to simplify design, reduce cost and avoid potential life time reduction. There are various kinds of material required for the purpose. The relative location of a ground fault along the length of the coil is determined by computing the. The coreless induction furnace is a refractory lined vesse l with electrical current carrying coils surrounding the refractory crucible. Induction heating is a precise, repeatable and efficient method of heating. Guidelines for proper coreless furnace maintenance. Induction furnaces basics of foundry melting furnaces. Induction furnace working through animation duration. To create the flux changes necessary to induce voltage in the secondary coil, the direct current in the primary coil is repeatedly interrupted by a vibrating. This crucible holds the charge material and subsequently the melt.
The channel induction furnace consists of a refractory lined steel shell which contains the molten metal. The induction coil is the output head of the induction heater. We, induction furnace components is one of the leading exporter,manufacturer,supplier,distributor,services provider of coil insulation material from rohini, delhi,india. The broad range includes induction furnace crucible parts that are made of superior grade raw materials.
A well designed coil provides the most desirable heat pattern as well as the best. A line to the plants power distribution panel typically furnishes power for the pumps in the induction coil cooling system, the hydraulic furnace tilting. The coil configuration and electrical parameters of the furnace are to be finalized to attain a temperature of about 1500 degc in 2 hours for the charge. This power calculation gives you approximate refrence value for your induction heating application. Coil design is considered from the outset in combination with the power supply. Coreless type induction furnace these furnaces fig. Heavywall, watercooled, extruded copper induction coil to maximize power efficiency. Attached to the steel shell and connected by a throat is an induction unit which forms the melting component of the furnace. What is induction heating and how do induction coils work. We, induction furnace components is one of the leading exporter,manufacturer,supplier,distributor,services provider of coil insulation material from. The induction coil actually functions as a transformer primary, with the workpiece to be heated becoming the transformer secondary. The following manual is no longer available in its. An induction coil consists of two coils of insulated wire wound around a common iron core m.
When the induction coil is placed next to or around a workpiece, the lines of force concentrate in the air gap between the coil and the workpiece. Eddy currents are induced in the metal charge, the circulation of these currents producing extremely high temperatures for melting the metals and for making alloys of exact composition. The discs diameters are in accordance with the standard billet diameters. Induction furnace cooling systems columbia steel casting. From the beginning, weve cast our reputation on providing worldclass induction melting furnace and coil service, repair, and rebuilds. Current flowing in one direction in the induction coil induces a current flow in the opposite. Build an induction heater and become a metalsmith hackaday. We supply complete range of insulation material required to reinsulaterepiar induction coil of any make. Anti heat loss design for molten metal hydraulic system secured by mechanical lock hydraulic furnace lid automatic lining removal system gas vacuuming system first class coil insulation. Basics of induction inductive heating is based on the supply of energy by means of electromagnetic induction.
The heat that builds up in the coil is constantly cooled with circulating water. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals. Unlike the melting and mass heating coils, the heat treating induction coils were machined. Induction furnace crucible parts induction furnace.
Induction furnace lining and industrial vibrator design. In the heating experiments, an induction coil that was designed to heat d178 mm aluminum billets was used. Temperature sensors, semi conductor fuses, thyristors, diodes, capacitors, carbon free hose pipes, water cooled cables, spare parts of crucibles, bus bars, selector switches, coils, insulating materials. Considering that the coil is located around heated liquid metal pool cooling water is circulated into the coil section. Design and fabrication of inductors for induction heat. Basically, the entire setup acts like a huge transformer with a shorted secondary. The crucible is formed from refractory material, which the furnace coils is lined with. I materials are acknowledged for the notable properties such as superior material strength and long functional life. Heavy steel shell to provide maximum furnace rigidity and strength for long lining life, low furnace noise and minimal emf emissions furnace load cells are available to provide accurate charge weight to simplify charge. Induction heating ih is a noninvasive heating technology 1 based on inducing an alternating magnetic field in a media to be heated fig. Pdf comparison of natural gas fired and induction heating. The magnetic field generated by the coil carries the energy to the charge. The induction heat treating coil style depends on the induction heat treating process. A copper coil encircles a layer of refractory material and a powerful electric current travels through the coils creating a magnetic field that penetrates the refractory and quickly melts the metal charge material inside the furnace.
Induction furnace and important operational aspects. The side wall of the furnace box is made using lm6 aluminium casting. Insulation material for induction furnace variety of material required for insulation of induction coil. The mockup facility will be used to demonstrate melting of 10 kg of copper in a graphite crucible and heated by induction furnace in a vacuum environment. To improve the latter, which seems to be the principal limitation, requires development of new materials to provide adequate strength, durability and electrical and thermal insulation in. Temperature sensors, semi conductor fuses, thyristors, diodes, capacitors, carbon free hose pipes, water cooled cables, spare parts of crucibles, bus bars, selector switches, coils, insulating materials, crucible repairing of melting.
Insulation materials are mainly use to insulate induction coil. An induction furnace is an electrical furnace in which the heat is applied by induction heating of metal. Current vibrators were not sufficent to cover all needs when lining induction furnace. Manufacturer of induction coil insulation materials induction furnace coil support, coil insulation material for induction furnace, induction furnance fiber glass tape and induction furnace mica tape offered by electro power engineers, ahmedabad, gujarat. Induction furnace cooling systems columbia steel casting co. Insulation material for induction furnace yoke mica. An induction heater operates by surrounding the object to be heated with a coil carrying high frequency ac current. Our range is known for the key features such as dimensional accuracy, rigid. Overheating the coil can cause coil insulation to deteriorate and develop coil toground or turntoturn problems. Our products induction furnace components is a pioneer name for furnaces and spares. In the induction furnace, a coil carrying alternating electric current surrounds the container or chamber of metal. Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. All induction heat treating processes can be classi.
Nov 16, 2016 induction furnace working through animation duration. Induction heating power calculation tool your induction. The choice of refractory material depends on the type of charge, i. Induction furnace spare parts manufacturer,furnace spare.
Nov 28, 2014 induction heating is a rapid clean nonpolluting heating. For maximum protection, the copper coil is insulated thrice using insulating material. However, in order to maximize the benefits of induction, its critical to have the correct system and coil design. A furnace is an equipment used to melt metals for casting or to heat materials to change their shape e. Thermal analysis of induction furnace comsol multiphysics. Induction heating an overview sciencedirect topics. Since the induction coil is a moveable component, it is connected using by. The good quality of material is utmost important, as induction coil operates at very high voltage and temperature. These furnace components are enclosed in stainless steel vacuum vessel.
Induction coil insulation materials induction furnace. Induction furnace capacities range from less than one kilogram to one hundred tonnes, and are used to melt iron and steel, copper, aluminium, and precious metals the advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process compared. Design and fabrication of inductors for induction heat treating. Any negligence about coil insulation results in failure of costly components and production loss. For sale is a unused kw inductotherm vip powertrak induction furnace full system for metal gold silver melting casting.
Comparison of natural gas fired and induction heating furnaces. Heating, the early induction heating coils were manufactured from copper tubing wrapped in multiple turns around a mandrel. A watermetal explosion can occur in any type of furnace. We are engaged in manufacturing a wide range of induction furnace crucible parts. The efficiency of induction heating is limited by the resistance of the primary winding and by the gap between the coil and the charge the filling factor. Online induction heating power calculation please fill out the parameters below for your theoretical induction heating process calculation. Then furnace heating schedule is to be followed carefully which will depend up thickness, nature of on the furnace lining ramming mass etc.
The induction unit consists of an iron core in the form of a ring around which a primary induction coil is wound. In a coreless induction furnace, the entire bath functions as the induction heating area. This is a powerful induction heater that can handle surges of upto 300 watts that is a lot of power to heat up any metal to red hot. Mediumfrequency coreless induction furnaces have evolved into the universal metallurgical solution for melting, holding and pouring a diverse range of metals.
Figure 1 shows the schematic layout of the equipment. For an induction furnace, however, the after effect may be more serious and include the possibility of additional explosions caused. Design analysis of an electric induction furnace for. Theory of heating by induction 7 tromagnetic, or flux around it. Our global team of highlyskilled engineers look forward to assessing your application and making the right recommendation for your process. Coil insulation s manufacturing is done using flexcoat. A metallic charge consisting of scra p, pig iron and. Induction heating is an accurate, fast, repeatable, efficient, noncontact technique for heating metals or any other electricallyconductive materials. Addressing this requirement, various technical solutions for. We doesnt provide induction furnace insulation products or service, please contact them directly and verify their companies info carefully.
Induction coil insulation materials our organization specializes in manufacturing a comprehensive array of induction coil insulation materials. For this purpose the molten metal bath must be earthed via an earthing rod in the bottom of the crucible. Emsco provides service and repair for induction melting furnaces of any size or oem. Features of induction furnace an electric induction furnace requires an electric coil to produce the charge. Induction coils are also designed for direct attachment to the induction heating power supply. Inspect all water connections for signs of leaks and test furnace water conductivity to ensure that the water meets the manufacturers specifications. This section introduces furnaces and refractories and explains the various design and operation aspects. Induction coil insulation materials induction furnace coil. The furnace coil shown in figure 14, during the heating process. In majority of papers on induction coil design the main attention is paid to optimization of active conductors, their position, number and size. Induction furnaces require two separate electrical systems. Design and implementation of an induction furnace diyala journal of engineering sciences, vol. Overheating the coil can cause coil insulation to deteriorate and develop coiltoground or turntoturn problems.
The basic principles of induction heating have been understood and applied to manufacturing since the 1920s. Pdf as a result of energy crisis, there is large innovation in heating and the electrical systems have progressed. Induction heating is a rapid clean nonpolluting heating. Ep0103394a1 methods of investigating ground faults. One coil, called the primary winding p, is made from relatively few tens or hundreds turns of coarse wire. Feb 05, 2018 this is a powerful induction heater that can handle surges of upto 300 watts that is a lot of power to heat up any metal to red hot. The advantage of the induction furnace is a clean, energyefficient and wellcontrollable melting process compared to most other means of metal melting. This earth fault monitoring system, although by now a standard feature on virtually all induction furnaces. Other articles where induction furnace is discussed. Induction furnace crucible parts induction furnace crucible.
Analysis of heat insulation for coil in the electromagnetic induction. Coil insulations manufacturing is done using flexcoat. Magneforce takes pride in providing our customers with the best coil type for the job. Finally, the optimum heat insulation method of induction coil was. Of the furnace and puts workers, the furnace itself and nearby plant and equipment at risk. Since the coil carries tank currents, it should be kept secure and protected to avoid short circuits or grounding of coil. Typically, the material to be heated is ferromagnetic and conductive and, consequently, induced currents, also called eddy or foucault currents, cause the material to be heated by joule effect.
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