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Induction preheating is a method of preheating metal workpieces using electromagnetic induction heating technology, widely used in welding, heat treatment, and other industrial applications.
Electromagnetic Induction: Induction preheating uses high-frequency alternating current to generate a magnetic field in an induction coil, which in turn induces eddy currents in the metal workpieces. These eddy currents generate heat due to the resistance of the metal, thereby heating the workpieces. This method can achieve rapid and uniform heating with high thermal efficiency.
Material Preparation: Place the metal workpieces to be preheated inside the induction coil.
Induction Heating: Generate a magnetic field in the induction coil through high-frequency current, inducing eddy currents to rapidly heat the workpieces.
Temperature Control: Precisely control the preheating temperature by adjusting the parameters of the power supply and induction coil.
Cooling: After preheating, the workpieces can be cooled or directly proceed to the next processing step.
Uniform Heating: Induction heating ensures uniform temperature across all parts of the workpieces, avoiding the inconsistent heating from flame or resistance methods.
Faster Cycle Times: Setup and heating times are significantly reduced, minimizing welder downtime.
Lower Energy Consumption: Due to the high efficiency of induction heating, most electrical energy is converted into heat, reducing energy waste.
Flexibility: Suitable for various shapes and sizes of workpieces, including complex geometries.
Increased Safety: Only the workpiece itself is heated, reducing the risk of burns and fire hazards for on-site workers.
Reduced Consumables: Reusable insulation and durable coils reduce the need for costly, disposable materials.
Welding: In welding applications, induction preheating can preheat the base material or the area around the weld joint, ensuring uniform welding temperature and reducing welding defects.
Heat Treatment: Used for preheating and post-heat treatment to improve the mechanical properties and corrosion resistance of materials.
Pipeline Construction: In pipeline welding, induction preheating can preheat the pipeline, reducing welding stress and deformation.
Other Industrial Applications: Including oil and gas, structural engineering, power plants, petrochemical/refineries, process/power piping, pressure vessels, shipyards, and mining.
At present, ordinary electric heating oil bath ovens are used for mold heating, and their main principle is to heat the mold through the wall heat radiation of the oven and the heat exchange between the hot air and the mold. Ordinary electric heating oil bath ovens have drawbacks such as long heating cycles, low heating efficiency, high experience requirements for operators, and high energy consumption. Induction heating, as a heating technology, has the characteristics of precise heating depth and heating area, high heating power, fast heating speed, high efficiency, low energy consumption, easy control of heating temperature, and easy automation of heating process. Since the 1930s, induction heating technology has been widely applied in industrial production, and has shown increasingly broad application prospects in many industrial fields. At the same time, the investment cost of induction heating equipment is low, especially with precise temperature control. Applying it to the powder warm pressing process will greatly improve the quality and production efficiency of molded products.
Three station mold induction heating preheating special equipment: continuous induction heating, preheating one mold every 60 seconds. The mold preheating is controlled by a three station integrated intelligent induction heating equipment for temperature closed-loop heating, preheating the mold to 150 ℃ for assembly. The temperature difference between the outer wall of the mold and the inner wall of the mold is small, which reduces the tendency of the internal temperature of the mold to overshoot. During the heating process, the temperature is stable and easy to control, improving production efficiency and product quality.
1) Adopting induction heating preheating method: high efficiency, fast preheating speed, multi stage temperature control in the preheating area, uniform preheating temperature, and no oxidation phenomenon;
2) Adopting the second-generation DSP intelligent induction heating equipment, it adopts power temperature dual closed-loop control, and can also achieve temperature curve control function, 4-point temperature display, and protection function. During the heating process, the overall temperature of the mold shall not exceed the set temperature by ± 3 ℃; At the end of heating, the temperature difference between various parts of the mold is less than 5 ℃; The heating power is adjustable, and feedback adjustment can be made based on the measured temperature of the mold, achieving insulation function.
3) The online thermocouple closed-loop control system has high temperature control accuracy, fast control speed, and real-time temperature display and recording.
4) Real time temperature alarm function, timely issuing alarm signals in case of abnormal production line rhythm, including high and low temperature alarms, heating timeout alarms, etc.
5) Professional online tooling positioning fixtures ensure accurate positioning of each mold during heating, ensuring temperature uniformity and preheating speed.
6) It has the function of switching between constant power, constant current, and constant temperature, making it convenient for heating applications with different loads.
7) Equipped with remote control and internal control operation mode switching, making it convenient to switch control modes.
8) It has a load matching indicator function, which facilitates intuitive guidance on load matching selection.
9) Equipped with device alarm status recording function, convenient for querying device historical data.
10) It has a hierarchical login function for administrators and operators to prevent unauthorized personnel from adjusting the heating process.
11) The intelligent DSP induction heating operation status and parameters such as voltage, current, power, frequency, etc. are collected and monitored in real-time. At the same time, these states can be directly connected to the centralized control network through the internal communication interface of the power supply, and the required parameters can be transmitted to other controllers such as industrial computers, CNC systems, laptops, remote control centers, etc. to meet the requirements of workshop Internet of Things.
