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A Training seminar on Induction Furnace

by Stead Fast Engineers Pvt. Ltd.

http://www.steadfastengg.co
m/

COMPANY PROFILE
Established in 1990, Stead Fast Engineers Pvt Ltd is an engineering

company engaged in designing and manufacturing of Induction


Melting furnaces, Induction Billet Heaters and Refractory Lining
Machines for Foundries, Steel Plants and Forging units. With the help
of years of experience and a highly skilled team, we create products
with attention to every minute detail thereby making the products
both user friendly and economical.
Stead Fast Engineers provides world class induction heating and
melting solutions for both ferrous and Non ferrous with a great focus
on customization so that every machine is nothing less than perfect.
With a family of more than 400 satisfied customers all over the
country and abroad, Stead Fast Engineers is expanding at a rapid
pace. With offices located in major cities we ensure that the service
is quick and effective and breakdown time is negligible. Adopting
stringent quality management systems during different stages of
production - the pre-process, In-process and pre-dispatch stage we
believe in manufacturing the best quality every time.

INDUCTION HEATING/MELTING
If an AC current is fed through a coil, the

electromagnetic field that is produced is constantly


changing. This changing magnetic field induces
electrical current (AC) in another circuit that is held
close .
This induced secondary current can be utilized to

generate heat in the circuit of the second conductor


by exploring the electrical losses due to the current.
These losses are due to Hysterises and Eddy current.

BLOCK DIAGRAM
Input current
&
voltage

Converter
control

DC
Choke

Inverter
control

3 Supply

Convert
Pulse

Invert
Pulse

PANEL
SL Card, ITC Card, Burden Card, Relay Card

Load
(Resistor)

ET- INDUCTION MELTING


FURNACE
ET-Induction Melting Furnace constitute following part:
Generator Panel
DC Choke
Coil Cradle Assembly
De-Mineralise Water Circulation Unit
Changeover Switch
Hydraulic Unit

GENERATOR PANEL
Generator Panel consist of following section:
3-phase Bridge Rectifier with freewheel diode.
(DC to AC) Inverter section
Starting Circuit
Control Electronic PCB Cards section
Transformer for power supply

3-phase Bridge Rectifier with


freewheel diode
Incoming mains 3- supply from furnace
transformer is rectified by Full Control Bridge
Rectifier.
Six identical Thyristor which are connected in Bridge

configuration to convert Incoming AC to


Corresponding DC. Six Thyristor stand for R+, R-,
Y+, Y-, B+ & B-.

(DC to AC) Inverter section


The inverter is responsible for converting High
Voltage DC to AC to feed it to the load circuit . It is
a single phase bridge Parallel Inverter
Thyristor are connected in four arms. Each arm
has serially stack thyristor in range of 3-4
depending of output Voltage designed. Thyristor
in diagonal pair are fired in each half cycle of
medium frequency , this frequency is determine
by parallel resonant LC circuit.

Starting Circuit
Starting circuit plays major role for
reliable starting of furnace.
It consist of Starting Card, Start
Capacitor, Start Choke, Start Thyristor
Module and Start Contactor unit.

ELECTRONIC CONTROL CARD


This section consist of following PCB cards:
ET-SL ( Sequence and Limit Control Card )
ET-ITC ( Inverter Control Card )
ET-TOV ( TOT Generation and Over voltage Detection)
ET-PS (Power Supply)
ET-SC ( Starting Card)
ET-133/2 ( Converter Firing Pulse Generation Card)
ET-133/3 (Amplification and Isolation Card)
ET-77 ( Inverter Firing Amplification and Isolation)
ET-84 ( Water Conductivity Measure )
ET-125 ( Earth Leakage Detection)
ET-BRDN ( Burden Board)
ET-RLY ( Relay )

ET-SL

ET-ITC

DC CHOKE
Works on the principle of transformer, I.e primary and
secondary are linked by magnetic flux. Transformer is
a electro-magnetic device so here in DC , Choke acts
only as resistance , which is in microohms.
DC chock converting pulsating DC to pure DC
It prevent thyrister of inverter from large current

COIL CRADLE ASSEMBLY

FURNACE COIL
It is made of high conductivity
For maximum efficiency of coil a

space is maintain by the spacer.


Additional stainless steel cooling
turn at the top and bottom is
clamped for providing uniform
cooling through out of the coil
cradel.

DEMINERALISE WATER
CIRCULATION
UNIT
DM water is deminrlised water.
DM water has very less conductivity (less
then 10/semens.
DM water is widely used for cooling purpose
of power equipments.
As for example in the coil cradel, change over
switch etc

CHANGE OVER SWITCH


This is offload switch used to alternately connect two furnace
crucible with single power source.
It can be operated manually or pneumatically. It is water cooled to
allow better heat dissipation.
The contacts points of switch is made by silver for better contacts.
The current carrying capacity is from 2KA to 20KA.

HYDRAULIC UNIT
This is the tilting structure of furnace
With the help of hydrolic unit we can tilt the furnace upto 95
Tilting process is done with the help of oil pressure which is

created by motor
The oil use for tilting is enklo-54 which has high viscous in

nature