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Know about automatic pouring system
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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
2
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
10
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
11
DUAL-TRAKDUAL-TRAK
12
DUAL-TRAKDUAL-TRAK
13
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
14
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
15
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
16
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
17
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
18
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
19
STEEL SHELL FURNACES -FUME HOOD
STEEL SHELL FURNACES -FUME HOOD
20
STEEL SHELL FURNACES - BACK TILT
SLAGGING
STEEL SHELL FURNACES - BACK TILT
SLAGGING
21
STEEL SHELL FURNACES -LOAD CELLS
STEEL SHELL FURNACES -LOAD CELLS
22
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
23
Sets the sinter recipe for furnace Starts and charts the sintering
process .
MELT MINDER - SINTER SCREENMELT MINDER - SINTER SCREEN
24
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
25
AUTOMATIC POURING SYSTEMSAUTOMATIC POURING SYSTEMS
26
FILLS THE MOULD
PROVIDES STORAGE
REDUCES MANPOWER
REDUCES REJECTS
AUTOMATIC POURING SYSTEMSAUTOMATIC POURING SYSTEMS
27
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
28
UNHEATED TUNDISH POURING SYSTEMUNHEATED TUNDISH POURING SYSTEM