800KW/6KHz 铜管退火中频炉2020新型

1、概述：

此加热装置，是我公司专为铜管在线退火而设计的，针对其在运动中进行连续加热及被加热工件为铜材的特点，在系统设计中对电源、感应器各参数应做特殊设计，整套系统采用一套800KW/6KHZ电源进行加热，感应器外部制作成铝质封闭外壳,内充保护性气体(氮气)以防铜管加热氧化,此系统具有以下特点：

1.1中频电源为800KW/6KHz。由于功率较大，频率较高，电源设计有一些特殊要求。这些将在电源的描述中详细说明。

1.2中频电源和感应器均采取水冷却方式，使设备的体积较小，容易安装。

1.3自动连续生产，可根据不同工件参数自动调整生产速度。

1.4生产线传输滚道采用变频调速，加上PLC可实现温度、速度、功率等的闭环控制。

2、工艺参数:

铜管尺寸: Φ9.52×0.37mm; Φ12.7×0.43 mm

铜管提升温度:700℃

辊道速度：＞200 m/min

3、系统设备运行方案：

3.1系统功率的选择:

加热总功率的选择根据贵方要求，选择为800KW。

3.2方案的选择：

根据加热工况为快速运行中加热的设备使用特点，由于感应加热的提温速度过快，无保温过程，从而影响铜管晶粒组织的细化过程，故该套系统采用脉冲式分段连续加热的方式，该种加热方式适用于连续式加热，是一种国外目前蕞先进的加热方式，这种加热方式可使铜管在经过无炉体部分有短时间的保温过程，这个保温过程在铜管的退火工艺中保证了其晶粒组织的细化过程，使其内部的晶粒细小、均衡，从而可使铜管退火后能达到贵公司的加工工艺要求。同时对于在加热炉体内的加热铜管不会引起轴向上的过大温差从而在某种程序上能克服热应力所造成的微观裂纹。

3.3 设备配置及加热工艺过程的实现：

将所需电源800KW/6KHZ为两台加热炉体供电，两台加热炉体对铜管进行加热，每台炉体对铜管进行一次快速提温后，经过短时间的保温过程，这个过程为无加热过程，为防止进入下一台感应炉时钢管低头而无法对准，中间设有机械滚轮装置定位；为了防止铜管加热过程的氧化，将两台炉体及导位部分装入一台密封的外壳之中，其中通入惰性气体；每台炉体的长度为400MM，机械滚轮装置与炉体之间的距离为单边20MM，炉体部分合计长度为800MM，考虑外壳占用部分空间，该加热部分总长度需1200MM即可。

将两台炉体和一套机械滚轮装置底座均固定在同一个炉体底座上，炉体的外壳为硬质铝合金，可同时起到保护气体密闭和磁屏蔽作用，使机架、滚轮等不被漏磁感应加热；炉体外壳设计为可拆卸式，对于炉体的检修、机械滚轮装置的更换均提供了方便。

3.4 控制系统及控制原理：

控制系统应实现两个过程的控制，其一为加热开始和结束时的速度-温度自动控制；其二为加热过程中的温度自动控制；这两个过程的实现硬件部分可借用贵公司设备上的PLC和人机界面，由我公司提供的数学模型编程，速度的采集由贵公司设备提供，温度的采集由我公司配置的远红外测温仪提供，功率调节接口我公司提供的中频电源已经具备，该接口为标准模拟信号接口（4-20MA或0-10V）。

3.4.1功率-速度-温度控制原理：

由于设备设计制造完毕之后，其系统阻抗(R)不会发生变化，功率给定只能是输出电压(U)或电流(I)的给定，而电流、电压与功率的关系为平方根关系，即P=U2/R=I2R；速度(S)、温度()和功率(P)之间的关系为线性关系，即：P=G/Sη(G)为与材料规格有关的系数，加热铜管一定时，该系数即不会发生变化。η为一个效率因子，初始值为经验参数。该参数取决于系统的整体运行状态，需要进行自学习整定。该控制系统为开环数据设定、闭环自学习整定效率因子η的自动控制系统。

3.4.2加热开始时的速度-温度控制

根据开始时的速度上升曲线，经数学模型计算出所需功率曲线对电源功率进行设定，系统按设定的功率曲线进行上升过程的加热。加热过程中通过测温仪测得的实际温度与工艺所需加热温度相比较后对效率因子进行修正。经过几次自动修正，以后加热就与工艺所需加热温度相吻合了。

3.4.3中段恒速时的温度控制

在中段恒速运行时，经数学模型计算出所需功率对电源功率进行设定，系统按设定的功率进行加热。加热过程中通过测温仪测得的实际温度与工艺所需加热温度相比较后对效率因子进行修正。经过几次自动修正。

800KW / 6KHz frequency heatingannealing brass

1 Overview:

his heating device is specially designed for the on-line annealing of copper tubes. For the characteristics of continuous heating in the movement and the workpiece being heated is copper, special design should be made for the parameters of the power supply and the inductor in the system design. he whole system is heated by a set of 800KW/6KHZ power supply. he outside of the inductor is made of aluminum closed casing and filled with protective gas (nitrogen) to prevent oxidation and oxidation of the copper pipe. his system has the following characteristics:

1.1 he intermediate frequency power supply is 800KW/6KHz.Due to the high power and high frequency, the power supply design has some special requirements.hese will be detailed in the description of the power supply.

1.2 he intermediate frequency power supply and the sensor are all water-cooled, making the equipment small and easy to install.

1.3 Automatic continuous production, the production speed can be automatically adjusted according to different workpiece parameters.

1.4 Production line transmission raceway adopts frequency conversion speed regulation, plus PLC can realize closed-loop control of temperature, speed and power.

2. Process parameters:

Copper tube size: Φ9.52×0.37mm; Φ12.7×0.43 mm

Copper tube lifting temperature: 700 ° C

Roller speed: >200 m/min

3. System equipment operation plan:

3.1 System power selection:

he choice of total heating power is 800KW depending on your requirements.

3.2 Choice of program:

According to the heating condition, the characteristics of the equipment used for heating in fast operation, because the heating speed of induction heating is too fast, there is no heat preservation process, thus affecting the refinement process of the copper tube grain structure, so the system adopts pulse type segmentation continuous he heating method is suitable for continuous heating. It is the most advanced heating method in foreign countries. his heating method can make the copper pipe have a short-term heat preservation process in the non- part. he annealing process of the copper tube ensures the refinement process of the grain structure, so that the internal crystal grains are fine and balanced, so that the copper tube can be annealed to meet the processing requirements of your company.At the same time, the heated copper tube in the heating body does not cause an excessive temperature difference in the axial direction, so that the micro crack caused by the thermal stress can be overcome in some procedures.

3.3 Equipment configuration and realization of the heating process:

he required power supply 800KW/6KHZ is used to supply two heating bodies, and two heating bodies heat the copper pipes. After each body performs a rapid temperature increase on the copper pipes, after a short time of heat preservation process, the process is here is no heating process. In order to prevent the steel pipe from falling into the next induction , it is impossible to align. he mechanical roller device is positioned in the middle. In order to prevent the oxidation of the copper tube heating process, the two bodies and the guiding part are loaded into one. Among the sealed outer casings, inert gas is introduced therein; the length of each body is 400 mm, the distance between the mechanical roller device and the body is 20 mm on one side, and the total length of the body portion is 800 mm, considering the space occupied by the outer casing, he total length of the heating portion needs to be 1200 MM.

he two bodies and a set of mechanical roller device bases are fixed on the same body base. he outer shell of the body is made of hard aluminum alloy, which can simultaneously protect the gas sealing and magnetic shielding, so that the frame, the roller, etc. It is not heated by magnetic flux leakage; the shell of the body is designed to be detachable, which provides convenience for the inspection of the body and the replacement of the mechanical roller device.

3.4 Control system and control principle:

he control system should realize the control of two processes, one is the speed-temperature automatic control at the beginning and the end of heating; the other is the automatic temperature control during the heating process; the hardware part of the two processes can be borrowed from your company equipment. he PLC and man-machine interface are programmed by the mathematical model provided by our company. he speed collection is provided by your company's equipment. he temperature collection is provided by the far-infrared thermometer configured by our company. he power adjustment interface is provided by the IF power supply provided by our company. Yes, the interface is a standard analog signal interface (4-20MA or 0-10V).

3.4.1 Power-speed-temperature control principle:

Since the system impedance (R) does not change after the device is designed and manufactured, the power can only be given by the output voltage (U) or current (I), and the relationship between current, voltage and power is square root. hat is, P=U2/R=I2R; the relationship between speed (S), temperature () and power (P) is linear, ie: P=G/Sη(G) is the coefficient related to the material specification, heating When the copper tube is fixed, the coefficient does not change.η is an efficiency factor and the initial value is an empirical parameter.his parameter depends on the overall operating state of the system and requires self-learning tuning.he control system is an automatic control system for setting open-loop data and closed-loop self-learning to set the efficiency factor η.

3.4.2 Speed-temperature control at the beginning of heating

According to the speed rise curve at the beginning, the required power curve is calculated by the mathematical model to set the power supply, and the system performs heating in the rising process according to the set power curve.he efficiency factor is corrected by comparing the actual temperature measured by the thermometer with the heating temperature required by the process during the heating process.After several automatic corrections, the subsequent heating is consistent with the heating temperature required for the process.

3.4.3 emperature control in the middle section at constant speed

During the constant speed operation in the middle section, the required power is calculated by the mathematical model to set the power supply, and the system is heated according to the set power.he efficiency factor is corrected by comparing the actual temperature measured by the thermometer with the heating temperature required by the process during the heating process.After several automatic corrections.

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