5t intemediate frequency furnace

郭珂/Guoke +86 132 9904 2234 Skype: guoke896884090

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5T

INTERMEDIATE FREQUENCY WITHOUT CORE INDUCTION

MELT COOKER TECHNOLOGY SCHEME

Summarize:

In this scheme, a set of equipment consist of two electric cooker

bodies, an intermediate frequency electrical source, a hydraulic pressure

equipment. A intermediate frequency electrical source supplies powers

for two electric cookers in which one are melting ,the other are standby.

Ⅰ. Technique parameter item Unit data

Electric cookers parameter Rating capacity t 5

Maximum capacity t 6

maximum working temperature ℃ 1750 electric parameter

transformer capacity KVA 3500 transformer first voltage KV 10

transformer second voltage V 750、750

intermediate frequency electrical source rating power

KW 3000

intermediate frequency electrical source maximum

output voltage

V 1500

working frequency Hz 250

transforming frequency % 98 start-up success frequency % 100

complex parameter fusion ratio(temperature was raised to 1600 ℃)

t/h 4.8

power cost of fusion (temperature was raised

KW·h/t 600



to 1600 ℃) working noises db =85

hydraulic pressure system station capacity L 500

working pressure Mpa 13 hydraulic pressure medium grease

cooling water system flow quantity t/h 144

water supply pressure Mpa 0.25-0.35 input water temperature ℃ 5-35

output water temperature ℃ ＜55

Ⅱ. Technical criterion and working condition of equipment

The parts of the equipment accord corresponding technical criterion listed

behind.

1. GBl0067.3— 88 the basic technical condition of

galvanothermy equipment— induction galvanothermy equipment.

2. GBl0063.3— 88 the experiment method of galvanothermy

equipment— non-core induction melting cooker.

3. GB5959.3-88 the safety of galvanothermy equipment— special

require on inductive and conductive heater and inductive melting

equipment.

4. JB4086-85 intermediate frequency non-core induction

heat-up use the technical condition of the equipments controlled by

electricity.

5. JB ／ T4280— 93 intermediate frequency non-core induction

cooker.

6. GB／T14549-93 the quality of power— the performance and



technical parameter of the resonance-wave equipment used in electricity

network reach the regulation of technology specification book.

Ⅲ. Normal working condition of the equipment listing behind

1. Environment

a. Altitude is below 1000 m.

b. Surroundings temperature is between 5 ℃ and 40℃.

c. Relative humidity is not above 90% (25℃).

d. No conductive dust, explosive gas and causticity gas which can

damage metal and insulation.

e. No obvious vibration and jounce.

2. Power supply demand

a. Power supply voltage in main circuit is 1OKV, fluctuation is less

5% and three phase imbalance is less 5%.

b. Power supply voltage in control system is 220 V and fluctuation is

less 5%.

c. Power supply voltage in main circuit and control system must be

sine wave whose shape aberration is less 10%.

3. The demand of cooling water in outside cycle

a. Overall rigidity is less 60 mg equal quantity per liter.

b. dissolutive solid substance < 300 mg／L.

c. PH 7— 8.5.

d. suspension solid substance < lOmg／L.



e. conductance rate <500µs／cm.

f. input water temperature =35℃.

Ⅳ. Technique explanation of electric parts

The electric parts of equipments consist of

electrical source commutation transformer,

Intermediate frequency electrical source cabinet,

compensation capacitor groups, and high voltage

switch cabinet.

1. Electrical source transformer

The electrical source transformer is used to

drop 11KV high voltage electricity in electric network to one which can

fit Intermediate frequency electrical source. The equipment adopts special

commutation transformers which self-cooling dipped in oil.

1.1 commutation transformer used for fusion:

rating capacity 3500 KVA

the first voltage 10 KV,

the second voltage 750 V。

impedance in short circuit between 6％ and 8％

non-load switch installed on the high voltage side and used to

regulate voltage by hand can adjust on three stages -5％，0，+5％.



1.2. Intermediate frequency

electrical source

The type of intermediate

frequency electrical source in the

electric cooker is KGPS -3000

/0.25.

Circuit principle drawing is listed

below.

2. Intermediate frequency electrical source main loop principle chart

2.1 Commutate part control silicon adopt up to date fold installed

radiator groupware as following chart

This kind of install mode is more convenience and science to remove

and install control silicon .When change control silicon, only loosen tip

tighten bolt, you can change anyone control silicon component in

groupware. Radiator component has scale which can consult when fasten,

and this guarantee right pressure during control silicon and radiator.

Moreover, this kind of installs mode minish control silicon groupware



volume, which makes operation room in electric cabinet bigger.

2.2 Great capacity direct current sieve wave reactor

Sieve wave reactor is very important for solid electrical source，it has

two function ，the one is to make output current smooth and stable；the

other is when athwart change control silicon short circuit，it circumscribe

short circuit increase rate and the biggest short circuit 。If sieve wave

reactor parameter design inconsequence，iron core material is not good or

production techniques do not pass the test ，all those may influence

reliability of intermediate frequency electrical source。

2.3 Athwart change circuit adopt great speediness control silicon

To guarantee athwart change circuit reliability，athwart change control

silicon adopt two big capacity KK silicon in series

2.4. Adopt series-parallel connection compensate circuitry to minish

wastage of transmit electricity circuitry

To minish intermediate frequency transmit electricity circuitry wastage,

athwart change circuit compensate capacitor adopt series-parallel

connection, as follows:

C1

L Intermediate C2

Frequency output

This kind connection can enhance cooker output voltage twice as



athwart change circuit. And at the same output power output electrical

current become only 50% as before, which make intermediate frequency

transmit circuitry wastage minish to 1/4.

2.5 Main circuit parameter and component selection foundation

When adopt 6 pulse wave rectifiers, commutate control silicon

average electrical current can be calculated according to the following

formula:

Ikpmax=Id max／2.72

Athwart change control silicon average electrical current can be calculate

according to the following formula:

Ikkmax=0.45XIdmax

Choose control silicon standard and select

2.6 Characteristic of intermediate frequency electrical source

2.6.1 Control system total numeric, without continue electricity control

Control system adopt ISP program logical array module to

integration control. Its core apparatus adopt high performance, high

density ,great standard special ASTC-2 integration circuit ,which is made

in USA, and this makes all signal

dispose and correspondence

operation carry out automatism

according to program. Replace all

kind of continue electricity control



with data control system to finish the function.

2.6.2 Unique browse frequency model startup mode has 100% startup

succeed rate.

Athwart change part adopt browse frequency zero pressure soft

startup ，which has better performance than common zero pressure soft

startup circuit。Browse frequency model startup process as following：

before startup，touch off athwart change

crystal brake pipe with stimulating signal whose frequency is higher than

slot route syntony， moreover control stimulate signal frequency to

browse from high to low，when the frequency is near slot route syntony，

intermediate frequency voltage is set up .To prevent intermediate

frequency voltage startup failure occasionally，our company design

automatism startup circuit，ensure 100% startup succeed rate，moreover ，

its response time is very short，it only takes less than 500 MSEL to finish

a automatism startup.

2.6.3 Adjuster with quick respond identity

Our company have design particular adjuster in control circuitry

whose responding time is very short, the adjuster is completely fit for the

use demand of speediness respond in the condition of the load break of

intermediate power supply.

2.6.4 Electrical source constant power is output to ensure supernal power



factor

The impedance adjuster is devised especially which can inspect the

change of the impedance and deliver it to circuit interior processing

figure operation and adjust automatically matching load to make

intermediate frequency power supply reach constant power. At the same

time, the running power factor of the whole set equipment reaches above

0.93 because of using impedance adjuster in the course of melting. The

relation graph of constant power intermediate frequency voltage US and

its corresponding power factor φcos is given in following drawing.

COS?

0

1050V 1300V Us

(Constant power intermediate frequency voltage and its

corresponding power factor connection graph)

2．6．5 Having outstanding anti-striking load capacity

There leave enough space in choosing main apparatus in system.，

which guarantee each apparatus outstanding anti-striking capacity。Our

firm provides especial device in control part of system on software, and



this makes system running more stationary and reliable and prevent

monocrystalline silicon efficiently from damage of electric impulse while

adding material .Thus, the equipment’s good capability of impulsion

resistance is ensured and the equipment can run on the safe side in long

period.

2.6.6 Perfect and reliable protection function

Such protection measure of overflow, overload, over press，phase

shortage, lack of voltage of controllable power, too low cooling water

pressure, too high temperature of cooling water and too low water flux

are provided in this controlling circuitry. These protection functions are

analyzed and realized by ASIC-2 integrate circuit, which ensures the

sensitivity and reliability of those protection function. This system is

water cooling equipment, real time inspection to cooling water on many

point has to be carried out for equipment runs on the safe side. Our firm

devises a set of characteristic inspect instrument for a special purpose aim

at importance of water inspection. Two temperature inspection points is

set on each controllable silicon, and the same points is set on each

syntonic capacitor and every induction loop. This makes each part of

water cooling of this system be inspected at real time. It is impossible to

damage part of apparatus which have too high water temperature on one

point.

2.6.7 Advanced auto identify function of phase order



A auto identify circuit of phase order is contained in controllable

system, which makes system need not install synchronic transformation

and excuse phase order modulation and the job to synchronize while

debugging and maintaining.

2.6.8 abundant outside controllable interface

It is set on the equipment that Out/In transformation, Auto/Hand

control switch and their interface, which can realize auto controlment

from long distance conveniently. And outside temperature ring

controllable interface is set to combine infrared temperature inspect

instrument and temperature auto controlling system, which can realize the

auto modulation of program enactment temperature rising to output

power of electrical source and makes final calefaction temperature of

steel tube reach anticipated temperature.

2.6.9 Light isolation impulse output

In controlling system, there are double isolation measures in

springing impulse between controlling board to controlling pole of

controllable silicon. Light isolation apparatus with its pressure endurance

over 2500V is used on controlling board to insulate springing impulse

from light or electricity, and transformer groupware with its pressure

endurance grade of over 3000V is used on impulse transformer. Even

though controllable silicon is stroked out because of over pressure, it has

little influence on controlling system.



2.6.10 Simple and convenient to debug and maintain

The major parameters’ settings on controlling board are finished by

internal circuit of controlling board. There are only six potentiometer

parameters’ settings which can be modulated by user. So the controlling

board is perfectly universal and reciprocates, and it is simple and

convenient to debug and maintain.

2.7 Cooker leaking protection and earthling alarm brake function

A special detector of cooker liner’s thickness is set on controlling

system. The working theory is to verdict the perfection of cooker liner

through leaking current between inductive loops and charging.

Because leaking current must amply while cooker liner becomes thin.

Alarm current of cooker liner thickness detector can be modulated.

Appropriate alarm current must be modulated gradually while it is being

used according to different size of cooker and different material of cooker

line.

Cooker liner thickness detector cann’t runs correctly 100 percent. It

can only offer reference of judging cooker liner thickness.

The cooker liner thickness detector is connected between side pole

and bottom pole directly.

2.8 Compensating capacitor

groups



To minish waste of big current circuit, compensating capacitor groups

are set on the position next to electric cooker in basement as possible as

they can.. All capacitor are new innoxious water cooling intermediate

frequency big capacity capacitors, which have such merit as big capacity

of each one, low waste of medium and small area of containing ground.

Digital temperature inspecting component is installed on each capacitor,

which can auto stop intermediate frequency electric source through

working temperature inspected by especial temperature inspection

appearance developed by our firm while temperature is over high and

alarm signal is come up.

Capacitor groups all use big section water cooling copper arrange.

Working temperature of copper arranges must not beyond C045 to cut

down transmission waste of parallel connecting syntonic circuit.

Five．Part of electric cooker

It contains electric cooker body, water cooling cable, high fire

endurance pastern, speedy extrusion equipment of cooker liner and

copper arrange of main circuit.

1. cooker body

Cooker body contains induction loop, magnetic yoke, cooker frame,

leaning oil jar and cooker cover.

1.1 Inductive loop



The inductive loop is circled by 99.99 percent rectangle copper cube.

Insulation on the inductive loop surface is smeared a flat of high strength

insulated colophony using static gushing craftwork, whose insulation can

endure voltage more than 6000V.

Inductive loop is fixed up by lists of bolts sealed around its

circumference and insulated supporting bar. After loop is fixed up, its

error of circle distance is no more than 2mm.

Copper water cooling circles are set on the top and the bottom of

inductive loop to make cooker liner material is heated evenly in axial

direction and to prolong the working life of cooker liner.

On the outside surface of inductive loop, couples of temperature

explorer stationeries are welded on waterway subsection to fix up

temperature measure component. While one of water way is jammed,

alarm is given off immediately and the intermediate frequency electric

source ceases automatically.

1.2 Magnetic yoke

The magnetic yoke is made up of cold rolled silicon and steel of

high magnetism transmit rate. The thickness of silicon and steel is o.3mm.

Profile modeling configuration is used in the magnetic yoke, whose

internal arc face radian is equal to outer circle’s radian of inductive loop.

This make the magnetic yoke can cling to outer side of inductive loop,

and inhibit the magnetic field emanated out by loop to decrease magnetic



block of outer magnetic circuit.

The magnetic yoke is hold by stainless steel plates on both sides and

stainless steel clamps. It is weld to root. Cooling water cubes are weld on

the stainless steel plates on both sides to cool magnetic yoke. The cooling

water cube can endure 0.45Mpa water pressure and has no leaking out in

15min.

After the magnetic yokes are installed completely, the camber is no

more than 4mm, the warp of theoretical center line and practical center

line are no more than 3mm.

1.3 cooker frames

The cooker frames divide into active part and stationary part.

Active cooker frame is used to install inductive loop and magnetic yoke,

which is weld by profiled bar and armor plate and utilize framework

configuration. The framework has removable cover board, which is

convenient for examine and repair. Deepen armor plates are used on the

operation flat roof on the top of cooker frame to enhance the intensity and

bearing ability of the cooker frame.

There is a cooker cover on the top of active cooker frame, and

hydraulic pressure driving fashion is used. The ascendance and rotation

of it are accomplished by two ole jars to ensure cooker cover to run in

gear and reliably

The stationary cooker frame is set on the groundsill to hold the active



cooker frame. There are leaning rolling axes connected to the cooker

frame over the stationary cooker frame, which can make active cooker

frame rotate 095 ahead. A fast cutting valve which can prevent breaking

and limit velocity is set on the bottom of the leaning cooker oil jar. In the

course of inclining cooker, if the ole jar is broken, the cutting valve which

can prevent breaking and limit velocity will act to cut off the returning oil

circuit of the oil jar and make the electric cooker state on the original

position.

There is a very big safety factor remained in the period of dividing.

This ensures that the cooker frame has enough rigidity and run placidly

when it bears the most loads.

Induction winding and charging parameter:

Induction winding and charging parameter is optimize designed by

special computer ，which guarantee the best electromagnetism coupling

efficiency at same capacity. Considering electric cooker need over take,

we design that rating capacity is bigger than standard .Only that can

guarantee charging liquid surface would not exceed water-cooling circle

upper surface at the biggest charging capacity. Since the part above

water-cooling circle is not cooled, if the part touches charging for long

time, it will produce high temperature, which makes cooker liner craze at

water-cooling circle.

2. water-cooling cable



water-cooling cable joint adopt cool pressure molding techniques to

press with copper wind line，which joint fastness，contact resistance

small，do not damnify copper wind line. The single tie-in and copper line

can endure more than 8t pull

Water-cooling cable outer bushing adopt special hinder-burning rubber

pipe, which is not flammability. Intension is good，which can endure

0.45Mpa water pressure.，no leak，no break。

material， which smear among circumference and inside induce

winding ，has following function：

（1）It makes induce winding whole，reduce vibration and noises when

work.

(2)when charging leak ，it can protect induce winding.

(3)It makes for pulling cooker liner.

4. Pulling cooker liner rapidly equipment

Pulling cooker liner rapidly equipment，which include tip push block，

tip push oil jar and operation framework, is used for getting rid of old

ones rapidly.

Tip push block，under cooker liner，is linked with tip push oil jar

through the bottom of cooker. when pushing out old cooker liner ，turn

the electric cooker 90 degree，fix tip push oil jar with bolt and joint flange.

Operate handy valve to press oil jar ，then old cooker liner is pushed out .



Six .hydraulic pressure

Including hydraulic pressure pumping station and leaning cooker

manipulation platform:

Hydraulic pressure pumping station is used for supplying power to

leaning cooker, cooker lip drive oil jar, cooker liner push oil jar. Pumping

station rating work pressure is 11Mpa. Hydraulic pressure medium is

hydraulic pressure oil.

Leaning cooker manipulation platform is used for controlling the

cooker to lean, turn round, switching cooker lip and pushing cooker

liner。 It adopt handle valve, act placidity, no impulsion.

All hydraulic pressure components adopt joint venture high quality

product.

Seven: cooling water system

Cooling water system adopts cooling tower of FBNL close type or

FKHL open type whose concrete parameter select may refer to the

data of sample production.

Eight: installation and base map

The installation of the facility and base map are showed in attached

drawing.

Nine: technique datum and drawing



We supply following technique datum when the equipment leave

factory.

1. machine part

It includes electric cooker exterior drawing, base drawing, plane lay

drawing, land build demand, the data of flat roof and cooling water

system, easy damage piece drawing.

Equipment fixing and debug instructor, the guidance book of use and

maintenance about electric cooker.

Hydraulic pressure principle drawing, the guidance book of the

Hydraulic pressure system.

The guidance book of the water system.

2. electric part

It includes the principle drawing of the electric and circuit, exterior

wiring diagram, electric component table, the guidance book of

intermediate frequency power supply, the guidance book of control

system malfunction inspection exclusion.

Ten: Equipment beforehand validate and training

When all the equipment manufacture is over, we will invite the buyer

technician to the equipment manufacture factory, take part in the

equipment beforehand check , accept and training.

1. beforehand check and accept content:



(1) commonly inspection

(2) security inspection

(3) the cooker assemble dimension examination

(4) inductorium manufacture quality examination and insulation,

pressure endurance experimentation

(5) measurement the electric gap between inductorium and cooker

shell

(6) measurement insulated resistance between inductorium and cooker

shell

(7) measurement insulated resistance between inductorium and

magnetism yoke

(8) intermediate frequency cooker insulated, pressure endurance test

(9) pressure test of hydraulic pressure system

(10) leaning cooker manipulate test of leaning cooker transmission

framework

(11) induction winding hydraulic pressure test

(12) electric linkage and spillage cooker alarming equipment

experiment

(13) electric malfunction display, monitor, alarm etc protect functional

inspection

(14) match inspection, including model, standard, up to grade certificate

leaving factory



(15) supply good range, technique document integrality test

2. Training

(1) The seller supply user the following technical training the equipment

installation training

(2) Electric control design principle training.(Including: electric design

protection, inspection, malfunction display)

(3) Equipment maintains and daily maintains work training

(4) Equipment ordinary malfunction and special malfunction elimination

training

3. All the beforehand check and accept item and test data should be got

when two sides attend and signature, supply user the data at the same

time.

4. Only when all the check work is over and two sides agree to sign it, the

seller can package and consignment the equipment

Twelve install, debug and the final check and accept.

Eleven: Installation, Debug and final check and accept.

1. When the equipment installation is over, our company will send respect

specialist install spot to check the installation and precision, and then

debug the equipment

2. The seller specialist will train the user employee to handle and repair

the equipment at the spot



3. The equipment final check and accept should be held at user spot, the

item including:

(1) all the check item and completely safety check;

(2) Induce cooker heat preservation power parameter measurement;

(3) Induce cooker heat preservation power measurement，temperature

rising productivity measurement

(4) Induce cooker electricity consume and melt rate measurement

(5) Refrigeration medium temperature rising measurement

(6) The cooker component temperature measurement

(7) Charging temperature measurement

(8) Noises measurement

(9) Check after heat condition experiment

(10) Alarm system dependability and sensitive degree examination;

(11) According to technical demand clausal validate

When all the item have been checked, tested, write out the final

examination report, both sides get agreement, the contract get into effect

Twelve: product quality control measure

1. Our company is strictly according to ISO9001 quality standard at

quality control, set up a completely quality system document and get

across quality authentication. When we select the oral material and in

addition fitting, we set up a whole and up to grade provider, to be sure the



quality of oral material.

2. In the process of the production, every spare part has quality

responsibility track card, which record every step responsibility and the

final check .to the pivotal part such as inductor ,magnetism yoke etc, we

have special technique regulations, which ensure that only the up to grade

part from last working procedure can get across the next.

3. We will checkout the product before leaving factory. Which include

appearance examination, mechanism measurement, induce winding

insulation checkout, bear the press and water trial. The lean movement

of .electric cooker examination cooker lid rise drop and circumrotate

examination.

4. Hydraulic pressure system check-out and each intermediate frequency

electrical source parameter examination ,when all the examination is up

to grade ,the checkout will fill product checkout certificate, and record all

kinds of examine data ,which guarantee product quality can trace back

Thirteen: product quality guarantee

1. The electric cooker facility is made up with bran-new, high–quality

material which can compare with equipment technique standard

explanation book; all substantiality facets are fitted with equipment

technical standard explaination book.

2. All the main outer fitting of equipment have product check-out



certification.

3. We guarantee to keep the electric cooker equipment in good repair for

twelve month since the final check-out. During the guarantee period,

all the malfunction caused by the equipment manufacture badness or

low quality of outer fitting, we will repair and change relevant part.

4. We provide 24 hour respond service .we will send to serve the user

during 24 hour in the country ,to abroad the time should take

transaction go abroad procedure into account depend on the

government work efficiency.

5. To be certain stability of production, we provide customers spare part

at benefit price which is lower than market price at same time.



The whole equipment sets includes

number device name model quantity

1 Frequency thyristor converter KGPS

KGPS-3000KW/0.25KHz 1

2 Link copper Between the power supply

to the capacitor 1

3 Capacitor bank 0.25KHz 1 4 Water-cooling cable set 2

5 Induction melting assembled unit

GWJ-5.0t 2

6 Hydraulic System 1 7 Crucible mould 2 8 Water Distributor 2 9 Operation Platform 1 10 Furnace leak alarm system 1 11 Lining ejector 1

5t intemediate frequency furnace

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