銅管退火中頻爐2020新型感應(yīng)電爐設(shè)備

800KW/6KHz 銅管退火中頻爐2020新型

1、概述：

此加熱裝置，是我公司專為銅管在線退火而設(shè)計的，針對其在運動中進行連續(xù)加熱及被加熱工件為銅材的特點，在系統(tǒng)設(shè)計中對電源、感應(yīng)器各參數(shù)應(yīng)做特殊設(shè)計，整套系統(tǒng)采用一套800KW/6KHZ電源進行加熱，感應(yīng)器外部制作成鋁質(zhì)封閉外殼,內(nèi)充保護性氣體(氮氣)以防銅管加熱氧化,此系統(tǒng)具有以下特點：

1.1中頻電源為800KW/6KHz。由于功率較大，頻率較高，電源設(shè)計有一些特殊要求。這些將在電源的描述中詳細說明。

1.2中頻電源和感應(yīng)器均采取水冷卻方式，使設(shè)備的體積較小，容易安裝。

1.3自動連續(xù)生產(chǎn)，可根據(jù)不同工件參數(shù)自動調(diào)整生產(chǎn)速度。

1.4生產(chǎn)線傳輸滾道采用變頻調(diào)速，加上PLC可實現(xiàn)溫度、速度、功率等的閉環(huán)控制。

2、工藝參數(shù):

銅管尺寸: Φ9.52×0.37mm; Φ12.7×0.43 mm

銅管提升溫度:700℃

輥道速度：＞200 m/min

3、系統(tǒng)設(shè)備運行方案：

3.1系統(tǒng)功率的選擇:

加熱總功率的選擇根據(jù)貴方要求，選擇為800KW。

3.2方案的選擇：

根據(jù)加熱工況為快速運行中加熱的設(shè)備使用特點，由于感應(yīng)加熱的提溫速度過快，無保溫過程，從而影響銅管晶粒組織的細化過程，故該套系統(tǒng)采用脈沖式分段連續(xù)加熱的方式，該種加熱方式適用于連續(xù)式加熱，是一種國外目前**的加熱方式，這種加熱方式可使銅管在經(jīng)過無爐體部分有短時間的保溫過程，這個保溫過程在銅管的退火工藝中保證了其晶粒組織的細化過程，使其內(nèi)部的晶粒細小、均衡，從而可使銅管退火后能達到貴公司的加工工藝要求。同時對于在加熱爐體內(nèi)的加熱銅管不會引起軸向上的過大溫差從而在某種程序上能克服熱應(yīng)力所造成的微觀裂紋。

3.3 設(shè)備配置及加熱工藝過程的實現(xiàn)：

將所需電源800KW/6KHZ為兩臺加熱爐體供電，兩臺加熱爐體對銅管進行加熱，每臺爐體對銅管進行一次快速提溫后，經(jīng)過短時間的保溫過程，這個過程為無加熱過程，為防止進入下一臺感應(yīng)爐時鋼管低頭而無法對準，中間設(shè)有機械滾輪裝置定位；為了防止銅管加熱過程的氧化，將兩臺爐體及導(dǎo)位部分裝入一臺密封的外殼之中，其中通入惰性氣體；每臺爐體的長度為400MM，機械滾輪裝置與爐體之間的距離為單邊20MM，爐體部分合計長度為800MM，考慮外殼占用部分空間，該加熱部分總長度需1200MM即可。

將兩臺爐體和一套機械滾輪裝置底座均固定在同一個爐體底座上，爐體的外殼為硬質(zhì)鋁合金，可同時起到保護氣體密閉和磁屏蔽作用，使機架、滾輪等不被漏磁感應(yīng)加熱；爐體外殼設(shè)計為可拆卸式，對于爐體的檢修、機械滾輪裝置的更換均提供了方便。

3.4 控制系統(tǒng)及控制原理：

控制系統(tǒng)應(yīng)實現(xiàn)兩個過程的控制，其一為加熱開始和結(jié)束時的速度-溫度自動控制；其二為加熱過程中的溫度自動控制；這兩個過程的實現(xiàn)硬件部分可借用貴公司設(shè)備上的PLC和人機界面，由我公司提供的數(shù)學(xué)模型編程，速度的采集由貴公司設(shè)備提供，溫度的采集由我公司配置的遠紅外測溫儀提供，功率調(diào)節(jié)接口我公司提供的中頻電源已經(jīng)具備，該接口為標準模擬信號接口（4-20MA或0-10V）。

3.4.1功率-速度-溫度控制原理：

由于設(shè)備設(shè)計制造完畢之后，其系統(tǒng)阻抗(R)不會發(fā)生變化，功率給定只能是輸出電壓(U)或電流(I)的給定，而電流、電壓與功率的關(guān)系為平方根關(guān)系，即P=U2/R=I2R；速度(S)、溫度()和功率(P)之間的關(guān)系為線性關(guān)系，即：P=G/Sη(G)為與材料規(guī)格有關(guān)的系數(shù)，加熱銅管一定時，該系數(shù)即不會發(fā)生變化。η為一個效率因子，初始值為經(jīng)驗參數(shù)。該參數(shù)取決于系統(tǒng)的整體運行狀態(tài)，需要進行自學(xué)習(xí)整定。該控制系統(tǒng)為開環(huán)數(shù)據(jù)設(shè)定、閉環(huán)自學(xué)習(xí)整定效率因子η的自動控制系統(tǒng)。

3.4.2加熱開始時的速度-溫度控制

根據(jù)開始時的速度上升曲線，經(jīng)數(shù)學(xué)模型計算出所需功率曲線對電源功率進行設(shè)定，系統(tǒng)按設(shè)定的功率曲線進行上升過程的加熱。加熱過程中通過測溫儀測得的實際溫度與工藝所需加熱溫度相比較后對效率因子進行修正。經(jīng)過幾次自動修正，以后加熱就與工藝所需加熱溫度相吻合了。

3.4.3中段恒速時的溫度控制

在中段恒速運行時，經(jīng)數(shù)學(xué)模型計算出所需功率對電源功率進行設(shè)定，系統(tǒng)按設(shè)定的功率進行加熱。加熱過程中通過測溫儀測得的實際溫度與工藝所需加熱溫度相比較后對效率因子進行修正。經(jīng)過幾次自動修正。

800KW / 6KHz frequency heatingannealing brass

1 Overview:

his heating device is specially designed for the on-line annealing of copper tubes. For the characteristics of continuous heating in the movement and the workpiece being heated is copper, special design should be made for the parameters of the power supply and the inductor in the system design. he whole system is heated by a set of 800KW/6KHZ power supply. he outside of the inductor is made of aluminum closed casing and filled with protective gas (nitrogen) to prevent oxidation and oxidation of the copper pipe. his system has the following characteristics:

1.1 he intermediate frequency power supply is 800KW/6KHz.Due to the high power and high frequency, the power supply design has some special requirements.hese will be detailed in the description of the power supply.

1.2 he intermediate frequency power supply and the sensor are all water-cooled, making the equipment small and easy to install.

1.3 Automatic continuous production, the production speed can be automatically adjusted according to different workpiece parameters.

1.4 Production line transmission raceway adopts frequency conversion speed regulation, plus PLC can realize closed-loop control of temperature, speed and power.

2. Process parameters:

Copper tube size: Φ9.52×0.37mm; Φ12.7×0.43 mm

Copper tube lifting temperature: 700 ° C

Roller speed: >200 m/min

3. System equipment operation plan:

3.1 System power selection:

he choice of total heating power is 800KW depending on your requirements.

3.2 Choice of program:

According to the heating condition, the characteristics of the equipment used for heating in fast operation, because the heating speed of induction heating is too fast, there is no heat preservation process, thus affecting the refinement process of the copper tube grain structure, so the system adopts pulse type segmentation continuous he heating method is suitable for continuous heating. It is the most advanced heating method in foreign countries. his heating method can make the copper pipe have a short-term heat preservation process in the non- part. he annealing process of the copper tube ensures the refinement process of the grain structure, so that the internal crystal grains are fine and balanced, so that the copper tube can be annealed to meet the processing requirements of your company.At the same time, the heated copper tube in the heating body does not cause an excessive temperature difference in the axial direction, so that the micro crack caused by the thermal stress can be overcome in some procedures.

3.3 Equipment configuration and realization of the heating process:

he required power supply 800KW/6KHZ is used to supply two heating bodies, and two heating bodies heat the copper pipes. After each body performs a rapid temperature increase on the copper pipes, after a short time of heat preservation process, the process is here is no heating process. In order to prevent the steel pipe from falling into the next induction , it is impossible to align. he mechanical roller device is positioned in the middle. In order to prevent the oxidation of the copper tube heating process, the two bodies and the guiding part are loaded into one. Among the sealed outer casings, inert gas is introduced therein; the length of each body is 400 mm, the distance between the mechanical roller device and the body is 20 mm on one side, and the total length of the body portion is 800 mm, considering the space occupied by the outer casing, he total length of the heating portion needs to be 1200 MM.

he two bodies and a set of mechanical roller device bases are fixed on the same body base. he outer shell of the body is made of hard aluminum alloy, which can simultaneously protect the gas sealing and magnetic shielding, so that the frame, the roller, etc. It is not heated by magnetic flux leakage; the shell of the body is designed to be detachable, which provides convenience for the inspection of the body and the replacement of the mechanical roller device.

3.4 Control system and control principle:

he control system should realize the control of two processes, one is the speed-temperature automatic control at the beginning and the end of heating; the other is the automatic temperature control during the heating process; the hardware part of the two processes can be borrowed from your company equipment. he PLC and man-machine interface are programmed by the mathematical model provided by our company. he speed collection is provided by your company's equipment. he temperature collection is provided by the far-infrared thermometer configured by our company. he power adjustment interface is provided by the IF power supply provided by our company. Yes, the interface is a standard analog signal interface (4-20MA or 0-10V).

3.4.1 Power-speed-temperature control principle:

Since the system impedance (R) does not change after the device is designed and manufactured, the power can only be given by the output voltage (U) or current (I), and the relationship between current, voltage and power is square root. hat is, P=U2/R=I2R; the relationship between speed (S), temperature () and power (P) is linear, ie: P=G/Sη(G) is the coefficient related to the material specification, heating When the copper tube is fixed, the coefficient does not change.η is an efficiency factor and the initial value is an empirical parameter.his parameter depends on the overall operating state of the system and requires self-learning tuning.he control system is an automatic control system for setting open-loop data and closed-loop self-learning to set the efficiency factor η.

3.4.2 Speed-temperature control at the beginning of heating

According to the speed rise curve at the beginning, the required power curve is calculated by the mathematical model to set the power supply, and the system performs heating in the rising process according to the set power curve.he efficiency factor is corrected by comparing the actual temperature measured by the thermometer with the heating temperature required by the process during the heating process.After several automatic corrections, the subsequent heating is consistent with the heating temperature required for the process.

3.4.3 emperature control in the middle section at constant speed

During the constant speed operation in the middle section, the required power is calculated by the mathematical model to set the power supply, and the system is heated according to the set power.he efficiency factor is corrected by comparing the actual temperature measured by the thermometer with the heating temperature required by the process during the heating process.After several automatic corrections.

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