Induction Furnace Power Supply
What is Induction Furnace Power Supply?
Induction furnace power supply power supply was developed to support and assure optimum performance. The power supply of the induction furnace takes a 3-phase frequency into a single-phase power at the desired frequency.
Why Choose Us
Production equipment
We produce a complete set of equipment, induction power supply, furnace body, and cooler for 100kw-20000kw medium frequency induction melting furnaces and induction heating furnaces, which can meet the casting, forging, and heat treatment needs of metals in different fields.
Our Company
The company not only has industry-leading technological level, but also has a complete pre-sales and after-sales service process. At present, the cumulative number of customers served by the company has exceeded 3000, and our good reputation among customers has enabled us to continuously expand into new customers.
Production Market
We have successfully won the trust and support of over 2000 customers worldwide, and have successfully sold to multiple countries and regions such as Southeast Asia, the Middle East, North Africa, Eastern Europe, Central Asia, and South America, becoming the preferred brand for many metal processing enterprises in these regions.
Our Certificates
In 2023, Hexinda Electric Furnace received a Copyright Registration Certificate for its computer software used in manufacturing, processing, and production operation control systems. Additionally, we hold two Utility Model Patent Certificates.
Before understanding the construction of the induction furnace power supply, you should know the internal components and their roles well. For the desired output, the power supply has several main parts. It works together to get the desired power.
Coils and inductors are the core of the power supply unit. Their function is to form a winding of the high-frequency transformer. The winding is both primary and secondary. The primary coil gets the electrical energy, and the secondary works to transfer it to the chamber, which creates a powerful electromagnetic field. The primary coil gets energy from an external source.
The following important components are capacitors and their banks, which regulate the power supply. The banks store energy to release it in controlled bursts later while ensuring a stable output. When the energy is controlled carefully, it helps the power supply to deliver the required power according to the demand of the induction furnace.
Lastly, the rectifiers and inverters convert AC into the DC, or in some situations, DC into AC.
Mainly it is a rectifier that converts AC into DC power that is then supplied to the inverter. (this process ensures an efficient utilization of power). At the same time, the inverter is the one that converts the DC into AC which is best for driving the primary coil. (to efficiently convert the power between two forms, it is efficient to use inverters and rectifiers.).
How Does Induction Furnace Power Supply Work?
Now that you know the fundamental comprehension of constructing an induction furnace power supply unit, let's explore its working principles. The process can be simplified into a few key steps:
Input Supply: The power supply source is a static line frequency to medium/high-frequency converter. Typically, industrial power is available at line frequency, 3-phase. However, induction furnaces require high-frequency power to be fed to the induction coil for heating/melting applications.
Rectification – The 3-phase incoming supply is fed to a 3-phase full wave rectifier. This rectifier converts the AC supply into a DC supply. During operation, the converter thyristors remain fired at a maximum firing angle, ensuring a continuous DC supply to the inverter while the power is on. The DC choke filters the rectified supply to smoothen the DC supply further.
Filtering – A L/C filter filters out the high-frequency ripples and ensures a smooth DC supply. This filtering prevents unwanted disturbances from going back to the mains.
Inversion (DC to AC Conversion) – The filtered DC supply is then fed to a transistorized inverter, which converts it back to an AC supply at the desired high frequency.
Output to Induction Furnace – That power is delivered to the primary coil (through the coil and inductor setup). That leads to the magnetic field that induces current in metal charge leading to metal heating and melting. The inverter can regulate the power delivered to the induction coil. The switching frequency of the inverter is varied to change the output power. The switching frequency is automatically adjusted to the required value depending on the power the operator demands.
What Are the Main Components of The Intermediate Frequency Induction Heating Power Supply?
During the use of the intermediate frequency induction heating power supply, its main components can be divided into four aspects, which are the power source electrical part, the furnace body part, the transmission device, and the water cooling system.
In terms of the power source and electrical part, the power equipment of the intermediate frequency induction heating power supply includes a high-voltage or low-voltage switchgear, a medium-frequency generator set or a controllable silicon frequency converter, a power conversion switch, a compensating capacitor, and an intermediate-frequency control cabinet. In some large intermediate frequency furnaces, the electrical part also includes a crucible leak furnace alarm system.
As for the furnace body part, both small and medium-sized intermediate frequency furnaces are equipped with two furnace bodies. One is used for production and the other is a backup. The furnace body includes a furnace cover, an inductor, a crucible, a furnace body bracket, etc. The transmission device of the intermediate frequency induction heating equipment includes a mechanical or hydraulic device such as moving the furnace cover and tilting and resetting the furnace body.
The water cooling system mainly includes the intermediate frequency power supply, the inductor, the capacitor, the busbar, and the soft cable, etc. To save water, circulating cooling methods are usually used. The cooling water circulation system includes a water pump, a cooling tower, a water tank, etc.
How Can I Improve My Induction Furnace Efficiency?
To improve the efficiency of your induction furnace, you can consider the following steps:
Change Your Operating Procedures: Shorten the holding times during melting to reduce energy consumption and increase the lifespan of your induction furnace.
Take Advantage Of Fast Heating: Induction furnaces work on the principle of induction, which allows for quicker heating compared to electric or gas heating methods. This faster heating process can improve efficiency and reduce overall melting time.
Optimize Startup Time: Induction furnaces have a quick startup time as full power is immediately available through the energy-efficient power supply. There is no need for a warm-up or cool-down cycle, allowing for faster production.
Benefit From Natural Stirring: Induction power supplies create a medium-frequency electric current that results in a strong stirring action within the liquid metal. This natural stirring helps to achieve a homogeneous mixture, improving the efficiency of the melting process.
Reduce Refractory Materials: Induction furnaces require less refractory materials compared to fuel-fired units. This can lead to cost savings and improved efficiency.
Focus On Energy Conservation: Induction furnaces are known for their energy efficiency. They can reduce power consumption during the melting process, resulting in lower energy costs and a reduced environmental impact.
Consider Compact Installation: Induction furnaces are available in various sizes and offer a compact installation compared to other larger and bulkier furnaces. This can save space and make overall operations more efficient.
Take Advantage Of Higher Production Rates: Due to the shorter melting time provided by induction furnaces, manufacturing companies can increase their production rates and meet higher demand.
Selection of Power Supply Unit in Induction Heating Furnace
Induction heating Furnace for your heating application : Electroheat Induction
Standard Power consumption for induction heating furnace and Induction forging application as per follow.
Induction forging application: 400-450 kWh/ton
Induction heating application: 400-450 kWh/ton
Below is the example for selection of induction power supply unit in Induction heating furnace for strip heating.
Strips dimensions: 60mm x 100mm x 38 mm
Material: Steel SAE 5160
Heating Temperature: 950-100°C
Required Heating Volume: 60mm x100mm x 38mm
Capacity requirement: 120 pieces / hour
So, effective volume for heating = 38 x 100 x 60
= 2.28 x 10^5 mm^3 Induction heating euipment for forging
Weight = Volume x Density
= 2.28 x 10^5 mm^3 x 0.0078 gm/mm^3
= 1778.4 gm
= 1.8kg
Now, required production rate is 120 pieces/ hour. So cycle time would be 30 second/piece. Here, we can consider 15-17 second for heating and 15-13 second for loading and unloading. Ideal production would be 240 pieces in one hour.
Total weight = 1.8 x 240
= 432 kg/ hour
As mentioned above, power consumption in Induction heating furnace is 400 kWh/ ton for heating steel
Required power = 432 kg/ hour x 400 kWh/1000kg
= 172.8 kW
So, 175 kW power supply unit required to achieve target production rate. Here, kWh/ ton are very important factor to calculate power. Each metals have different kWh/ton at different temperature and application. Its depends on type of metal, temperature, application, size of the induction heating furnace, system design etc.
Main Applications of Thyristors - Power Semiconductor Devices
Thyristors, commonly known as silicon-controlled rectifiers (SCRs), find widespread applications in various electronic systems owing to their unique electrical properties. These semiconductor devices are primarily employed in power control and conversion circuits. One significant application involves their use in voltage regulation, where thyristors play a crucial role in maintaining stable and controlled electrical output. Additionally, thyristors are integral components in phase-locked loop (PLL) circuits, ensuring precise synchronization and frequency control in electronic systems. Moreover, they are extensively utilized in motor control applications, contributing to the efficient and controlled operation of electric motors. The versatility of thyristors extends to their use in pulse-width modulation (PWM) techniques for achieving variable speed control in diverse applications, such as industrial drives and robotics. The main applications of thyristors encompass power control, voltage regulation, phase synchronization, motor control, and pulse-width modulation, making them indispensable components in modern electronic systems.
Application of Thyristor-based UPS Power Supply: Battery Soft Start
The circuit diagram of a soft starter is a crucial element in motor control systems, designed to mitigate the inrush current during the starting phase of electric motors. A key component enhancing the functionality of this circuit is the thyristor. The soft starter circuit typically consists of a thyristor-based voltage control mechanism that regulates the power supplied to the motor during startup. The importance of the thyristor in this context lies in its ability to control the conduction angle, allowing for a gradual and controlled increase in voltage to the motor. By employing the thyristor, the soft starter ensures a smooth and step-less acceleration of the motor, preventing sudden spikes in current that could lead to mechanical stress and electrical disturbances. This controlled startup not only reduces mechanical wear and tear on the motor but also enhances the overall efficiency of the system. The thyristor's role in the soft starter circuit is indispensable, providing a reliable means to optimize motor performance and prolong equipment lifespan in various industrial applications.
Applications of Thyristors in UPS Power Supplies – Modularization
The circuit diagram of a modular UPS main circuit is designed with modularity in mind, enhancing the flexibility and scalability of uninterruptible power supply (UPS) systems. In this setup, thyristors play a pivotal role in controlling power flow and facilitating seamless transitions between different modules within the UPS system. Thyristors efficiently regulate and switch high-power loads, allowing the modular UPS to distribute power among various modules, optimizing energy usage, and improving overall system reliability. The modular architecture enables easy expansion or maintenance without disrupting the entire system, making the UPS adaptable to changing power requirements. Therefore, the inclusion of thyristors in the modular UPS main circuit is crucial for creating a robust and scalable power supply solution capable of meeting diverse needs in a dynamic operational environment.
Applications of Thyristors - Static Bypass Switches (STS)
A static bypass switch circuit diagram typically comprises a set of components designed to allow for the seamless transfer of electrical power from the main supply to an alternative path. In this circuit, the inclusion of a thyristor is of paramount importance. The thyristor serves as a key switching element that enables the controlled diversion of power when needed. The circuit design ensures that, under normal operating conditions, the thyristor remains non-conductive, allowing power to flow through the primary path. However, in the event of a fault or maintenance requirement, the thyristor can be triggered to conduct, creating a low-resistance path and facilitating the transfer of power to the bypass route. This controlled switching is crucial for ensuring uninterrupted power supply during critical moments without causing disruption or downtime. The thyristor's role in the static bypass switch circuit is central to achieving a reliable and efficient mechanism for diverting power when necessary, thus enhancing the overall reliability and availability of the electrical system.
Our Factory
Shandong Hexinda Electric Furnace Co., Ltd. was established in 2014. After 10 years of development, the company has become a production-oriented company that integrates research and development, production, sales, and after-sales service, and has passed ISO9001 quality system certification. We produce a complete set of equipment, induction power supply, furnace body, and cooler for 100kw-20000kw medium frequency induction melting furnaces and induction heating furnaces, which can meet the casting, forging, and heat treatment needs of metals in different fields. The company not only has industry-leading technological level, but also has a complete pre-sales and after-sales service process.
FAQ
We're well-known as one of the leading induction furnace power supply manufacturers and suppliers in China. If you're going to buy customized induction furnace power supply, welcome to get more information from our factory.
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