1GREEN AUTOMATION 2007

Aug 2-3, 2007

LATEST TRENDS IN INDUCTION MELTING AND AUTOMATIC

POURING SYSTEMS

GREEN AUTOMATION 2007

Aug 2-3, 2007

LATEST TRENDS IN INDUCTION MELTING AND AUTOMATIC

POURING SYSTEMS

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3MELTING & POURING SYSTEMSMELTING & POURING SYSTEMS

4HEATING & HARDENING SYSTEMSHEATING & HARDENING SYSTEMS

5TUBE & PIPE WELDING SYSTEMSTUBE & PIPE WELDING SYSTEMS

61. Fastest Melt Rates.

2. Lower energy consumption.

3. Lower kVA requirement.

4. Higher power factor & Lower Harmonic distortion.

5. Safety.

Basic Requirements from an Induction Furnace -Productivity , Operating Cost , Safety

Basic Requirements from an Induction Furnace -Productivity , Operating Cost , Safety

7BASIC PRINCIPLE

CURRENT FLOW HEATS THE METAL CHARGE

BASIC PRINCIPLE

CURRENT FLOW HEATS THE METAL CHARGE

8A CONSTANT DC VOLTAGE IS

APPLIED TO THE INVERTER

THREE PHASES OF AC ARE CONVERTED TO

SINGLE PHASE DC. DC ENERGY STORED IN

CAPACITORS

THE FURNACE COIL AND CAPACITOR BANK ARE CONNECTED IN SERIES

VOLTAGE-FED INVERTER TECHNOLOGY APPLIED BY INDUCTOTHERM

VOLTAGE-FED INVERTER TECHNOLOGY APPLIED BY INDUCTOTHERM

9The VIP Power-Trak Systems track the power regardless of changing furnace conditions. Full power from start to finish for fastest melting.

POWER-TRAKING ACHIEVES

FASTEST MELT RATES

POWER-TRAKING ACHIEVES

FASTEST MELT RATES

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A full melting cycle consist of the time for-

1. Initial Charging2. Melting3. Deslagging4. Chemistry Analysis and Adjustment5. Pouring

Utilization Factor = Melting timeCycle time

DUAL-TRAKDUAL-TRAK

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DUAL-TRAKDUAL-TRAK

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DUAL-TRAKDUAL-TRAK

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Power utilization of almost 100%.

Batch production capability of two power supplies in a

single unit.

25 to 30% more metal output for a given kVA.

Uninterrupted metal flow.

Availability of liquid metal from both furnaces if

required.

Power sharing between two furnace in any ratio.

ADVANTAGES OF A DUAL TRAKADVANTAGES OF A DUAL TRAK

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Steel Shells hoop strength gives the furnace superior strength.

Rugged construction minimizes distortion during tilting and pouring.

Low noise level because of sound deadening characteristics of solid steel shell.

STEEL SHELL FURNACES -STRUCTURAL STRENGTH

STEEL SHELL FURNACES -STRUCTURAL STRENGTH

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Thick walled coils reduce coil losses and put more energy into the metal.

Open Coil spacing enhances coil efficiency.

Appropriately contoured & larger coverage of magnetic shunts for re-directing electro-magnetic field into the metal and to reduce excessive shell heat-up.

Insulated furnace lids minimize radiation losses.

Cooling coils extend lining life.

STEEL SHELL FURNACES HIGHLY EFFICIENT

STEEL SHELL FURNACES HIGHLY EFFICIENT

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Shell Protects the coil in the event of metal splash. Serves as barrier between the splashed metal and the coil.

Higher freeboard protects workers from excessive heat when the lid is off.

Open bottom provides superior ventilation reducing moisture build-up and damage in the event of metal run-out.

Fume rings/Fume hoods are provided to remove smoke and fumes to protect workers from air pollution.

STEEL SHELL FURNACES SAFE TO OPERATE

STEEL SHELL FURNACES SAFE TO OPERATE

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GLD Probe

Wire ToGround Pusher Block

Bottom Of Furnace Shell

Probes Must Be in Contact With Metal

Bottom of Metal Bath

The Ground Leak Detector system includes both GLD module associated with Power Supply and GLD probe located in the furnace. The system indicates and shuts off the power when metal penetrates the furnace lining into the coil or when excessive moisture is present in the furnace or when low ground resistance exists in the electric system.

SUPERIOR GROUND LEAKAGE DETECTOR SYSTEM

SUPERIOR GROUND LEAKAGE DETECTOR SYSTEM

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Hydraulically powered push-out mechanism distributes pressure uniformly up the side walls of the refractory. The complete lining can be removed almost entirely in one piece .

Rammed Lining

Coil

Pusher BlockExtended

Furnace

Pusher Block

Removable Push-OutMechanism

SUPERIOR LINING PUSH-OUT TECHNOLOGY

SUPERIOR LINING PUSH-OUT TECHNOLOGY

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STEEL SHELL FURNACES -FUME HOOD

STEEL SHELL FURNACES -FUME HOOD

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STEEL SHELL FURNACES - BACK TILT

SLAGGING

STEEL SHELL FURNACES - BACK TILT

SLAGGING

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STEEL SHELL FURNACES -LOAD CELLS

STEEL SHELL FURNACES -LOAD CELLS

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1. Displays power, weight, and

temperature readings.

2. Displays temperature set

points (Normal operating

mode).

3. Displays kilowatt-hour total

(kWatt hour operating

mode).

4. Displays general furnace

information.

MELT MINDER - FURNACE DETAILS SCREENMELT MINDER - FURNACE DETAILS SCREEN

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Sets the sinter recipe for furnace Starts and charts the sintering

process .

MELT MINDER - SINTER SCREENMELT MINDER - SINTER SCREEN

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Displays, charts and prints selectable information for all heats over 24-

hour period for a specific date

MELT MINDER - STRIP CHART SCREENMELT MINDER - STRIP CHART SCREEN

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AUTOMATIC POURING SYSTEMSAUTOMATIC POURING SYSTEMS

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FILLS THE MOULD

PROVIDES STORAGE

REDUCES MANPOWER

REDUCES REJECTS

AUTOMATIC POURING SYSTEMSAUTOMATIC POURING SYSTEMS

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1

1 Vessel

3 3 Outlet

4

4 Inductor

5

5 Pressure supply

6

6 Float

7

7 Stopper

2

2 Inlet

PRESSURE POURING FURNACEPRESSURE POURING FURNACE

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UNHEATED TUNDISH POURING SYSTEMUNHEATED TUNDISH POURING SYSTEM