The induction heating power source has the highest heating efficiency and the fastest speed for metal materials, and is low in environmental protection. It has been widely used in various industries for the thermal processing, heat treatment, thermal assembly and welding, smelting and other processes of metal materials. The induction heating power supply consists of two parts, one is the AC power supply that provides energy, also called the variable frequency power supply; the other part is the induction coil that completes the electromagnetic induction energy conversion, called the inductor.
Induction heating power technologySeries and parallel
Induction heating power inverters mainly have parallel inverters and series inverters. The output of the series inverter can be equivalent to a low-impedance voltage source. When the two voltage sources are connected in parallel, the amplitude, phase and frequency of each other. Different or fluctuating will lead to a large circulation, so that the current of the inverter device is seriously uneven. Therefore, the parallel inverter has difficulty in parallel expansion; and for the parallel inverter, the DC large reactor at the input of the inverter It can act as a current buffer between each parallel inverter, so that the AG/DG or DG/DG link at the input has enough time to correct the deviation of DC current, achieve multi-machine parallel expansion, transistorized super audio, high frequency current Parallel inverter structures are often used, and parallel inverters are easy to be modularized and large-capacity is one of the main reasons.
The load of the induction heating power supply is various, and the power inverter and the load are an organic whole. The matching transformer is used to connect the power supply and the load sensor. The matching transformer for the high frequency and super audio power supply is from the magnetic material to the winding. The structure is being further optimized and improved. At the same time, three passive components can be replaced by three passive components from the circuit topology to eliminate the transformer and achieve efficient and low-cost matching.
Induction heating power supplies, thyristors, transistors and tube tubes can be produced in China. Thyristor power supplies have been in production for many years. IGBT power supplies are more user-friendly because of their advantages. The IGBT power supply has high electrical efficiency and low voltage, but the price is high, and it is gradually replacing the high-frequency power supply of the tube. Portable small-scale high-frequency power supplies are widely used in China because of their low price and convenience, and even enter foreign markets.
Annealing and tempering applications
Annealing heats the workpiece to the appropriate temperature, uses different holding times depending on the material and workpiece size, and then slowly cools (slowest cooling rate) in order to achieve or close the equilibrium of the metal internal organization for good process performance and performance. Or prepare for further quenching.
There are several advantages to using induction heating instead of gas or furnace for preheating. Thermal conduction can be carried out directly, which will minimize heat loss and energy loss, increase production efficiency and improve product quality. At the same time, the heat can be precisely controlled, which can reduce the temperature during welding and thus reduce the cooling rate. In addition, it also helps to reduce the risk of cold cracking and hardening. With induction heating, you don't have to face the hot gas, which improves the working environment, reduces the need for heat dissipation system, and reduces the risk of fire.
Characteristics and applications of high frequency induction heating power supply The main advantages of induction heating equipment are:
1 It is not necessary to heat the whole, the deformation of the workpiece is small, and the power consumption is small.
2 pollution-free.
3 The heating speed is fast, and the surface of the workpiece is oxidized and decarburized lightly.
4 Surface hardened layer can be adjusted as needed and easy to control.
5 Induction heating equipment can be installed on the machining production line, easy to mechanize and automate, easy to manage, and can reduce transportation, save manpower and improve production efficiency.
6 The hardened layer has a fine martensite structure and high hardness, strength and toughness. 7 After surface quenching, the surface of the workpiece has large compressive internal stress, and the workpiece has high resistance to fatigue and breakage. Induction heating heat treatment also has some disadvantages. Compared with flame quenching, induction heating equipment is more complicated and less adaptable, and it is difficult to guarantee quality for some complex shapes.
Induction heating equipment is widely used for surface quenching of gears, shafts, crankshafts, cams, rolls, etc., in order to improve the wear resistance and fatigue fracture resistance of these workpieces. The rear half shaft of the car is quenched by induction heating, and the number of fatigue cycles under the design load is about 10 times higher than that of the quenching and tempering treatment. The workpiece material that is inductively heated and quenched is generally medium carbon steel. In order to meet the special needs of certain workpieces, low-hardenability steels for induction heating surface quenching have been developed. Workpieces made of high carbon steel and cast iron can also be quenched by induction heating. The quenching medium is usually a water or polymer aqueous solution.
The equipment for induction heat treatment is mainly composed of power supply equipment, quenching machine and sensor. The main function of the power supply device is to output an alternating current with a suitable frequency. The high-frequency current power supply device has two types of tube high-frequency generators and thyristor inverters. The IF current power supply unit is a generator set. Generally, the power supply device can only output current of one frequency. Some devices can change the current frequency, or can directly use the 50 Hz power frequency current for induction heating.
The choice of high frequency induction heating power supply equipment is related to the depth of the heating layer required for the workpiece. For workpieces with deep layer heating, power supply equipment with lower current frequency should be used; for workpieces with shallow heating layer, power supply equipment with higher current frequency should be used. Another condition for selecting a power device is device power. As the heated surface area increases, the required power supply increases accordingly. When the heating surface area is too large or the power supply power is insufficient, a continuous heating method may be employed to relatively move the workpiece and the inductor, the front side is heated, and the rear side is cooled. However, it is best to heat the entire heated surface once. In this way, the hardened surface layer can be tempered by the residual heat of the workpiece core, thereby simplifying the process and saving energy. The main function of the induction heating quenching machine is to position the workpiece and perform the necessary movements. A device for providing a quenching medium should also be attached. Quenching machines can be divided into standard and special machines. The former is suitable for general workpieces and the latter is suitable for mass production of complex workpieces.
In order to ensure the heat treatment quality and improve the thermal efficiency during induction heat treatment, it is necessary to design and manufacture an appropriate structure sensor according to the shape and requirements of the workpiece. Commonly used sensors include external surface heating sensor, internal hole heating sensor, flat heating sensor, universal heating sensor, special heating sensor, single heating sensor, composite heating sensor, melting furnace, etc. .
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