INDUCTOTHERM INDUCTOTHERM HEADQUARTERS
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1 MAY 11-13, 13, 2010 SHERATON SURREY BC CANADA
2 INNOVATIONS OF MEDIUM FREQUENCY INDUCTION MELTING BY CHFINKJR INDUCTOTHERM CORP
3 INDUCTOTHERM INDUCTOTHERM HEADQUARTERS
4 MEDIUM FREQUENCY MELTING
5 MELT SHOP IN THE NEW MILLENNIUM
6 WHAT IS INDUCTION FURNACE AN INDUCTION FURNACE IS AN ELECTRICAL FURNACE IN WHICH HEAT IS APPLIED BY INDUCTION HEATING OF A CONDUCTIVE MEDIUM (METAL) IN A CRUCIBLE PLACED IN A WATER COOLED ALTERNATING CURRENT SOLENOID COIL.?
7 TWO TYPES OF INDUCTION MELTING FURNACES CORELESS FURNACE CHANNEL OR CORE TYPE FURNACE
8 TWO TYPES OF INDUCTION MELTING FURNACES CORELESS CHANNEL OR CORE
9 EARLY CORELESS INDUCTION MELT SYSTEMS IN 1950 S WERE POWERED BY HIGH FREQUENCY MOTOR GENERATORS WERE POWERED BY 60 HERTZ (MAINS) POWER SUPPLIES WERE NOT VERY FLEXIBLE AND REQUIRED A LOT OF OPERATOR ATTENTION THE OPERATOR HAD TO BE A OCTUPUS TO KEEP UP WITH THE CHANGES OF CAPACITOR AND TRANSFORMER TAPS INDUCTOTHERM
10 50 KW 3 KC MG SET WITH 75 HP MOTOR 1960
11 666 KW 1 KC MG SET WITH 1000 HP MOTOR 1950
12 MAINS FREQUENCY 60 HZ UNIT
13 60 HERTZ AIR COOLED CAPACITOR RACK
14 MAINS FREQUENCY CONTROL PANEL
15 WHAT DOES FREQUENCY MEAN? FREQUENCY: THE NUMBER OF PERIODS OF A REPETITIVE FUNCTION PER UNIT OF TIME FURNACE FREQUENCY: THE NUMBER OF TIMES PER SECOND THAT AN ALTERNATING CURRENT CHANGES FROM POSITIVE SIGNAL TO A NEGATIVE SIGNAL. CALLED CYCLES PER SECOND OR HERTZ
16 WHAT IS MEDIUM FREQUENCY OPERATING FREQUENCIES ABOVE 60 HERTZ BUT BELOW 1 KC - EXAMPLES: 100/150 HERTZ 200/300 HERTZ 300/400 HERTZ 500/700 HERTZ?
17 WHAT DOES KW MEAN? KILOWATTS - A UNIT OF POWER OR ELECTRICAL ENERGY ONE KW EQUALS 1000 WATTS OF ENERGY ONE WATT = ONE AMPERE TIMES ONE VOLT INDUCTION FURNACES ARE RATING IN KW OR MEGAWATTS ONE KW = ABOUT 1.34 HP
18 RANGES OF INDUCTION SYSTEMS TO DATE 15 KW TO 23,000 KW MELTING 15 KW TO 42,000 KW HEATING 5 LBS TO 250 TONS CAPACITY
19 INDUCTOTHERM RANGE OF CORELESS INDUCTION COILS
20 50 POUND HAND POUR FURNACE INDUCTOTHERM
21 70 TON FURNACE POWERED BY 23 MEGAWATTS
22 INDUCTION COIL
23
24 INDUCTOTHERM EDDY CURRENTS
25
26 MAGNETIC STIRRING
27 STIRRING VS FURNACE SIZE KW AND FREQUENCY
28 FURNACE SIZE VS FREQUENCY CHART INDUCTOTHERM
29 MEDIUM FREQUENCY FURNACES VS MAINS DOES NOT REQUIRE STARTER BLOCKS AS DOES MAINS FREQUENCY CAN MELT SCRAP WITH SMALLER CROSS SECTION CAN BE USED AS BATCH MELTERS OR LOW HEEL MELTERS FURNACE SIZE IS SMALLER FOR THE SAME KW APPLIED CAN BE EMPTIED AT THE END OF THE DAY OR WEEK DEPENDING ON SIZE REQUIRES LESS REFRACTORY BECAUSE THE FURNACE SIZE IS TYPICALLY SMALLER CAN BE EASILY EMPTIED AND RESTARTED WITH DIFFERENT ANALYSIS IRON IN BATCH MELT MODE FURNACE COMPONENTS ARE SMALLER THUS LOWER COST LOWER HOLDING POWER DUE TO SMALLER FURNACE SHORTER TIME REQUIRED TO RELINE
30 MELTING WITH MEDIUM FREQUENCY IS NOT NEW! FIRST 180 HERTZ SYSTEM BUILT IN 1961 USING TOROIDAL TRIPLERS FIRST 540 HERTZ SYSTEM BUILT IN 1965 ALSO USING TRIPLERS THE LARGEST 180 HERTZ TRIPLER SYSTEM WAS RATED AT 3600 KW WITH 20 TON FURNACE IN 1972 USING TRIPLERS INDUCTOTHERM
31 180 HERTZ MELT SYSTEM KW AND 3000 LB FURNACE
32 EARLY SOLID STATE POWER SUPPLIES INTRODUCED TO THE FOUNDRY INDUSTRY IN 1967 USED STUD MOUNTED TYPE SCRS USED MANY CONTROL BOARDS VERY COMPLEX FOR UNITS IN THE 500 KW RANGE
33 STUD MOUNTED SCR-- SILICON CONTROLLED RECTIFIER IN 1967 RATED 125 AMPS
34 INDUCTOTHERM HOCKEY PUCK SCR TODAY
35 TYPICAL HOCKEY PUCK RATINGS 53 MM SCR 2000 AMPS 77 MM SCR 4000 AMPS 100 MM SCR 5500 AMPS
36 HOCKEY PUCK SCRS THE CONTINUED DEVELOPMENT OF MORE POWERFUL HOCKEY PUCK SCRS HAS MADE IT POSSIBLE TO PROVIDE MELTING SYSTEMS ABLE TO APPLY 1000 KW PER METRIC TON OF FURNACE SIZE IN THE 100 TO 300 HERTZ RANGE.
37 SCR ASSEMBLY SCR SCR
38 1500 KW 200 HERTZ POWER SUPPLY SCR INVERTER SECTION
39 1500 KW 200 HERTZ POWER SUPPLY SCR RECTIFIER SECTION
40 MEDIUM FREQUENCY CAPACITORS IN HZ CAPACITORS WERE RATED AT 300 KVAR TODAY MEDIUM FREQUENCY CAPACITORS ARE RATED AS HIGH AS 5500 KVAR OR HIGHER REQUIRE MUCH LESS SPACE AND LESS WATER COOLING
41 AC WATER COOLED CAPACITORS
42 1500 KW 200 HZ POWER SUPPLY CAPACITOR SECTION
43 CONTROL BOARDS REDUCED TO ONE
44 SOLID STATE POWER SUPPLY RATED 10, KW 200 HZ INDUCTOTHERM
45 INDUCTOTHERM SIMPLIFIED CONTROLS
46 BATCH MELTING VS HEEL MELTING
47 SINGLE POWER SUPPLY WITH SWITCHES
48 DUAL OUTPUT SYSTEM -1991
49 ARTIST CONCEPTUAL LAYOUT
50 TRIPLE OUTPUT SYSTEM -1997
51 20,000 KW TRIPLE OUTPUT SYSTEM
52 FUTURE MULTIPLE OUTPUT SYSTEM FOR 100 TONS/HR
53 COMPUTER CONTROLS
54 FURNACE WEIGHING LOAD CELLS
55 DIGITAL CONTROLS NETWORKS
56 CLOSE CAPTURE FUME COLLECTION AND BACK SLAGGING
57 10 METRIC TON FURNACE AND TRANSVERSE INDEXING CHARGE CAR
58 AUTOMATED CHARGE CONVEYORS WITH ACOUSTIC ENCLOSURES
59 PUSHOUT LINING REMOVAL SYSTEM
60 PUSHOUT LINING REMOVAL SYSTEM
61 LINING INSTALLATION UNITS
62 BOTTOM VIBRATOR
63 FORM VIBRATOR
64 SAVEWAY LINING MONITOR SYSTEM
65 SAVEWAY ELECTRODE PANEL INSTALLATION
66 SAVEWAY OPERATIONAL DISPLAY
67 ARMS SYSTEM - AUTOMATED ROBOTIC MELT SHOP
68 ARMS-AUTOMATED AUTOMATED ROBOTIC MELT SHOP
69 MELT SHOP SAFETY! WORKING WITH MOLTEN METALS HAS ALWAYS BEEN A DANGEROUS JOB. TODAYS HIGH EFFICIENCY INDUCTION FURNACES HAVE IMPROVED WORKING CONDITIONS BY MAKING FOUNDRIES COOLER, CLEANER AND GENERALLY LESS HOSTILE FOR THE OPERATORS. THEY HAVE NOT HOWEVER ELIMINATED THE DANGERS INHERENT IN WORKING WITH MOLTEN METALS!
70 THE INDUCTION FOUNDRY SAFETY TRAINING KIT
71
72 THANK YOU!
73 QUESTIONS?
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