A variable frequency super large alloy induction melting furnace device

Abstract

The present invention discloses a variable frequency super-large alloy induction melting furnace device, which belongs to the technical field of large-scale metallurgical smelting equipment, and includes a variable frequency induction melting furnace unit, a capacitor compensation unit, a vacuum circuit breaker unit, and a PLC control unit. The variable frequency induction melting furnace unit includes two variable frequency induction melting furnaces, which are variable frequency induction melting furnace 1 and variable frequency induction melting furnace 2. The capacitor compensation unit includes multiple groups of compensation capacitors, which are marked and sorted in sequence in the form of compensation capacitor 1 and compensation capacitor 2. The variable frequency super-large alloy induction melting furnace device, by setting a PLC control unit, controls multiple groups of vacuum circuit breakers to realize automatic timely and appropriate switching of multiple groups of capacitor compensation, ensures that the load changes in real time and always runs at full power, thereby improving electrical efficiency, shortening melting time, and winning ample time for the preparation of subsequent processes, thereby improving the production efficiency of the entire smelting process.

Description

Technical Field

[0001] The invention belongs to the technical field of large-scale metallurgical smelting equipment, and in particular relates to a variable frequency super-large alloy induction smelting furnace device. Background Art

[0002] With the rapid development of my country's national economy, impact loads such as high-power melting furnaces are widely used in the industrial field. At present, with the large-scale development of induction melting furnaces, the tonnage capacity is getting larger and larger, but the larger the tonnage capacity, the higher the power consumption cost of the melting furnace, the lower the smelting production efficiency, and there are certain problems in the operation and maintenance of the equipment. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention provides a variable frequency super-large alloy induction melting furnace device to solve the problems raised in the above background technology.

[0004] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a variable frequency super-large alloy induction melting furnace device, comprising a variable frequency induction melting furnace unit, a capacitor compensation unit, a vacuum circuit breaker unit, and a PLC control unit, wherein the variable frequency induction melting furnace unit comprises two variable frequency induction melting furnaces, the two variable frequency induction melting furnaces are variable frequency induction melting furnace 1 and variable frequency induction melting furnace 2, the capacitor compensation unit comprises a plurality of groups of compensation capacitors, which are sequentially marked and sorted in the manner of compensation capacitor 1 and compensation capacitor 2, the vacuum circuit breaker unit comprises a plurality of groups of vacuum circuit breakers, which are sequentially marked and sorted in the manner of vacuum circuit breaker 1 and vacuum circuit breaker 2, and the PLC control unit is used to control the plurality of groups of vacuum circuit breakers to realize automatic timely and appropriate switching of the plurality of groups of compensation capacitors for compensation, so that the real-time change of the load always runs at full power;

[0005] The power interface of the variable frequency induction melting furnace unit is electrically connected to the input end of the variable frequency power module, the input end of the variable frequency power module is electrically connected to the output end of the rectifier voltage module, and the input end of the rectifier voltage module is electrically connected to the external power grid;

[0006] The output signal of the PLC control unit is connected to the signal input of the vacuum circuit breaker unit, the output signal of the vacuum circuit breaker unit is connected to the signal input of the capacitance compensation unit, the input of the capacitance compensation unit is electrically connected to the output of the capacitance monitoring module, and the capacitance monitoring module is used to collect voltage and current parameters of multiple groups of compensation capacitors in the capacitance compensation unit in real time;

[0007] An induction coil unit is arranged inside the variable frequency induction melting furnace unit. The induction coil unit is applied to the induction melting furnace coil on the variable frequency induction melting furnace. An upper water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged above the equipment of the induction coil unit. A lower water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged below the equipment of the induction coil unit. A temperature sensing module is also arranged in the permanent layer of the variable frequency induction melting furnace unit. The temperature sensing module is used to provide temperature detection of the entire area near the induction coil unit.

[0008] To further optimize the technical solution, the rectifier voltage module is a 24-pulse large rectifier transformer. The current of the external power grid is non-sinusoidal and contains many high-order harmonics. In order to reduce the harmonic pollution to the power grid and to improve the power factor, the pulse number of the rectifier equipment is selected as 24 pulses, which is used to rectify, stabilize and stabilize the voltage and current from the external power grid.

[0009] To further optimize this technical solution, the main technical parameters of the variable frequency super-large alloy induction melting furnace device are as follows:

[0010] Incoming line voltage: 1900V

[0011] Incoming current: 3343A

[0012] Output voltage: 6600V

[0013] Output power: 40000kW

[0014] Operating frequency: 150Hz

[0015] Furnace capacity: 90~100t.

[0016] To further optimize the technical solution, the multiple groups of vacuum circuit breakers in the vacuum circuit breaker unit and the multiple groups of compensation capacitors in the capacitor compensation unit are controlled one-to-one, and the multiple groups of compensation capacitors in the capacitor compensation unit are switched in three gears according to the switching amount, and the three-gear switching compensation capacitors are divided into three gears: high, medium and low.

[0017] To further optimize the technical solution, the induction coil unit includes an induction coil module 1 and an induction coil module 2, and the induction coil module 1 and the induction coil module 2 are respectively wound on the equipment of the variable frequency induction melting furnace 1 and the variable frequency induction melting furnace 2.

[0018] To further optimize the technical solution, when the induction coil module 1 and the induction coil module 2 are winding the coils, an inductance elimination module is provided on the induction coil module 1 and the induction coil module 2. The inductance elimination module is used to eliminate the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding discharge and sparking problems between the induction coil and the water-cooling coil.

[0019] To further optimize the technical solution, the variable frequency induction melting furnace one and the variable frequency induction melting furnace two are both equipped with a water cooling device unit and a hydraulic device unit, the water cooling device unit is used to provide a water cooling function, and the hydraulic device unit is used to monitor the operating status of the equipment.

[0020] To further optimize the technical solution, the temperature sensing module is a Raman distributed optical fiber sensor, which is embedded in a permanent layer close to the induction coil unit and utilizes the transmission characteristics of light waves in optical fibers to measure the temperature field distribution near the induction coil unit in real time.

[0021] Compared with the prior art, the present invention provides a variable frequency super-large alloy induction melting furnace device, which has the following beneficial effects:

[0022] 1. The variable frequency super-large alloy induction melting furnace device, by setting up an inductance elimination module, minimizes the leakage flux, effectively solves the weakness of high power consumption of weak magnetic alloy (nickel, chromium, etc.) induction furnace melting, eliminates the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding the discharge and ignition problem between the induction coil and the upper and lower water-cooling coils, especially for high-power and high-voltage induction furnaces, providing more effective protection for equipment maintenance and efficient operation.

[0023] 2. The variable frequency super-large alloy induction melting furnace device is equipped with a PLC control unit. The PLC controls multiple groups of vacuum circuit breakers to realize automatic timely and appropriate switching of multiple groups of capacitor compensation, ensuring that the load changes in real time and always runs at full power, thereby improving electrical efficiency, shortening the melting time, and winning ample time for the preparation of the subsequent process, thereby improving the production efficiency of the entire smelting process. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic diagram of the connection structure of a variable frequency induction melting furnace unit in a variable frequency super-large alloy induction melting furnace device proposed by the present invention;

[0025] Figure 2 A schematic diagram of the working process of a variable frequency super-large alloy induction melting furnace device proposed by the present invention;

[0026] Figure 3 The present invention provides a schematic diagram of the connection structure of a vacuum circuit breaker unit and a capacitor compensation unit in a variable frequency super-large alloy induction melting furnace device. DETAILED DESCRIPTION

[0027] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] Embodiment 1:

[0029] like Figure 2 and Figure 3 As shown, a variable frequency super-large alloy induction melting furnace device includes a variable frequency induction melting furnace unit, a capacitor compensation unit, a vacuum circuit breaker unit, and a PLC control unit. The variable frequency induction melting furnace unit includes two variable frequency induction melting furnaces, which are variable frequency induction melting furnace 1 and variable frequency induction melting furnace 2. The capacitor compensation unit includes multiple groups of compensation capacitors, which are sequentially marked and sorted in the manner of compensation capacitor 1 and compensation capacitor 2. The vacuum circuit breaker unit includes multiple groups of vacuum circuit breakers, which are sequentially marked and sorted in the manner of vacuum circuit breaker 1 and vacuum circuit breaker 2. The PLC control unit is used to control multiple groups of vacuum circuit breakers to realize automatic timely and appropriate switching of multiple groups of compensation capacitors for compensation, so that the real-time change of the load always runs at full power;

[0030] The power interface of the variable frequency induction melting furnace unit is electrically connected to the input end of the variable frequency power module, the input end of the variable frequency power module is electrically connected to the output end of the rectifier voltage module, and the input end of the rectifier voltage module is electrically connected to the external power grid;

[0031] The output signal of the PLC control unit is connected to the signal input of the vacuum circuit breaker unit, the output signal of the vacuum circuit breaker unit is connected to the signal input of the capacitance compensation unit, the input of the capacitance compensation unit is electrically connected to the output of the capacitance monitoring module, and the capacitance monitoring module is used to collect voltage and current parameters of multiple groups of compensation capacitors in the capacitance compensation unit in real time;

[0032] like Figure 1 As shown, the variable frequency induction melting furnace unit is internally provided with an induction coil unit, the induction coil unit is applied to the induction melting furnace coil on the variable frequency induction melting furnace, an upper water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged above the equipment of the induction coil unit, a lower water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged below the equipment of the induction coil unit, and a temperature sensing module is further arranged in the permanent layer of the variable frequency induction melting furnace unit, the temperature sensing module is used to provide temperature detection of the entire area near the induction coil unit.

[0033] Specifically, the rectifier voltage module is a 24-pulse large rectifier transformer. The current of the external power grid is non-sinusoidal and contains many high-order harmonics. In order to reduce the harmonic pollution to the power grid and to improve the power factor, the pulse number of the rectifier equipment is selected as 24 pulses, which is used to rectify, stabilize and stabilize the voltage and current from the external power grid.

[0034] Specifically, the main technical parameters of the variable frequency super-large alloy induction melting furnace device are as follows:

[0035] Incoming line voltage: 1900V

[0036] Incoming current: 3343A

[0037] Output voltage: 6600V

[0038] Output power: 40000kW

[0039] Operating frequency: 150Hz

[0040] Furnace capacity: 90~100t.

[0041] Specifically, the multiple groups of vacuum circuit breakers in the vacuum circuit breaker unit and the multiple groups of compensation capacitors in the capacitance compensation unit are controlled in a one-to-one correspondence, and the multiple groups of compensation capacitors in the capacitance compensation unit are switched in three gears according to the switching amount, and the three-gear switching compensation capacitors are divided into three gears: high, medium and low.

[0042] Specifically, the induction coil unit includes an induction coil module 1 and an induction coil module 2, and the induction coil module 1 and the induction coil module 2 are respectively wound on the equipment of the variable frequency induction melting furnace 1 and the variable frequency induction melting furnace 2.

[0043] Specifically, when the induction coil module 1 and the induction coil module 2 are winding the coils, an inductance elimination module is provided on the induction coil module 1 and the induction coil module 2. The inductance elimination module is used to eliminate the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding discharge and sparking problems between the induction coil and the water-cooling coil.

[0044] Specifically, the first variable frequency induction melting furnace and the second variable frequency induction melting furnace are both equipped with a water cooling device unit and a hydraulic device unit. The water cooling device unit is used to provide a water cooling function, and the hydraulic device unit is used to monitor the operating status of the equipment.

[0045] Specifically, the temperature sensing module is a Raman distributed optical fiber sensor, which is embedded in a permanent layer close to the induction coil unit and uses the transmission characteristics of light waves in optical fibers to measure the temperature field distribution near the induction coil unit in real time.

[0046] Embodiment 2:

[0047] A variable frequency super-large alloy induction melting furnace device, comprising a variable frequency induction melting furnace unit, a capacitor compensation unit, a vacuum circuit breaker unit, and a PLC control unit, wherein the variable frequency induction melting furnace unit comprises two variable frequency induction melting furnaces, the two variable frequency induction melting furnaces being variable frequency induction melting furnace 1 and variable frequency induction melting furnace 2, the capacitor compensation unit comprises a plurality of groups of compensation capacitors, which are sequentially marked and sorted in the manner of compensation capacitor 1 and compensation capacitor 2, and specifically five groups of compensation capacitors are provided, the vacuum circuit breaker unit comprises a plurality of groups of vacuum circuit breakers, which are sequentially marked and sorted in the manner of vacuum circuit breaker 1 and vacuum circuit breaker 2, and specifically five groups of vacuum circuit breakers are provided, and the PLC control unit is used to control the plurality of groups of vacuum circuit breakers to realize automatic timely and appropriate switching of the plurality of groups of compensation capacitors for compensation, so that the real-time change of the load always operates at full power;

[0048] The power interface of the variable frequency induction melting furnace unit is electrically connected to the input end of the variable frequency power module, the input end of the variable frequency power module is electrically connected to the output end of the rectifier voltage module, and the input end of the rectifier voltage module is electrically connected to the external power grid;

[0049] The output signal of the PLC control unit is connected to the signal input of the vacuum circuit breaker unit, the output signal of the vacuum circuit breaker unit is connected to the signal input of the capacitance compensation unit, the input of the capacitance compensation unit is electrically connected to the output of the capacitance monitoring module, and the capacitance monitoring module is used to collect voltage and current parameters of multiple groups of compensation capacitors in the capacitance compensation unit in real time;

[0050] The PLC control unit may also be a central processing unit (CPU), other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware plug-ins, etc. The general-purpose processor may be a microprocessor or the processor may also be any conventional processor, etc.

[0051] An induction coil unit is arranged inside the variable frequency induction melting furnace unit. The induction coil unit is applied to the induction melting furnace coil on the variable frequency induction melting furnace. An upper water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged above the equipment of the induction coil unit. A lower water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged below the equipment of the induction coil unit. A temperature sensing module is also arranged in the permanent layer of the variable frequency induction melting furnace unit. The temperature sensing module is used to provide temperature detection of the entire area near the induction coil unit.

[0052] Specifically, the rectifier voltage module is a 24-pulse large rectifier transformer. The current of the external power grid is non-sinusoidal and contains many high-order harmonics. In order to reduce the harmonic pollution to the power grid and to improve the power factor, the pulse number of the rectifier equipment is selected as 24 pulses, which is used to rectify, stabilize and stabilize the voltage and current from the external power grid.

[0053] Specifically, the main technical parameters of the variable frequency super-large alloy induction melting furnace device are as follows:

[0054] Incoming line voltage: 1900V

[0055] Incoming current: 3343A

[0056] Output voltage: 6600V

[0057] Output power: 40000kW

[0058] Operating frequency: 150Hz

[0059] Furnace capacity: 90t.

[0060] Specifically, the multiple groups of vacuum circuit breakers in the vacuum circuit breaker unit and the multiple groups of compensation capacitors in the capacitance compensation unit are controlled in a one-to-one correspondence, and the multiple groups of compensation capacitors in the capacitance compensation unit are switched in three gears according to the switching amount, and the three-gear switching compensation capacitors are divided into three gears: high, medium and low.

[0061] Specifically, the induction coil unit includes an induction coil module 1 and an induction coil module 2, and the induction coil module 1 and the induction coil module 2 are respectively wound on the equipment of the variable frequency induction melting furnace 1 and the variable frequency induction melting furnace 2.

[0062] Specifically, when the induction coil module 1 and the induction coil module 2 are winding the coils, an inductance elimination module is provided on the induction coil module 1 and the induction coil module 2. The inductance elimination module is used to eliminate the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding discharge and sparking problems between the induction coil and the water-cooling coil.

[0063] Specifically, the first variable frequency induction melting furnace and the second variable frequency induction melting furnace are both equipped with a water cooling device unit and a hydraulic device unit. The water cooling device unit is used to provide a water cooling function, and the hydraulic device unit is used to monitor the operating status of the equipment.

[0064] Specifically, the temperature sensing module is a Raman distributed optical fiber sensor, which is embedded in a permanent layer close to the induction coil unit and uses the transmission characteristics of light waves in optical fibers to measure the temperature field distribution near the induction coil unit in real time.

[0065] Embodiment three:

[0066] A variable frequency super-large alloy induction melting furnace device described in Example 1 or Example 2 is used. After actual use, it is measured that the unit power consumption of the variable frequency super-large alloy induction melting furnace device is 482kw.h / t (the final temperature of the furnace charge is 1600℃), which is better than the first-class (535≤N≤580kw.h / t). The rated effective furnace charge (T) [technical requirement ≥70] of the variable frequency super-large alloy induction melting furnace device is tested to be 70, and the power factor [technical requirement ≥0.86] of the variable frequency super-large alloy induction melting furnace device is tested to be 0.94. It also solves the weakness of high power consumption of the induction furnace for melting weak magnetic alloys (nickel, chromium, etc.), eliminates the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding the problem of discharge and ignition between the induction coil and the upper and lower water-cooling coils, especially for high-power and high-voltage induction furnaces, providing more effective guarantees for equipment maintenance and efficient operation.

[0067] The beneficial effects of the present invention are:

[0068] 1. The variable frequency super-large alloy induction melting furnace device, by setting up an inductance elimination module, minimizes the leakage flux, effectively solves the weakness of high power consumption of weak magnetic alloy (nickel, chromium, etc.) induction furnace melting, eliminates the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding the discharge and ignition problem between the induction coil and the upper and lower water-cooling coils, especially for high-power and high-voltage induction furnaces, providing more effective protection for equipment maintenance and efficient operation.

[0069] 2. The variable frequency super-large alloy induction melting furnace device is equipped with a PLC control unit. The PLC controls multiple groups of vacuum circuit breakers to realize automatic timely and appropriate switching of multiple groups of capacitor compensation, ensuring that the load changes in real time and always runs at full power, thereby improving electrical efficiency, shortening the melting time, and winning ample time for the preparation of the subsequent process, thereby improving the production efficiency of the entire smelting process.

[0070] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0071] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A variable frequency super-large alloy induction melting furnace device, characterized in that: It includes a variable frequency induction melting furnace unit, a capacitor compensation unit, a vacuum circuit breaker unit, and a PLC control unit. The variable frequency induction melting furnace unit includes two variable frequency induction melting furnaces, which are variable frequency induction melting furnace 1 and variable frequency induction melting furnace 2. The capacitor compensation unit includes multiple groups of compensation capacitors, which are sequentially marked and sorted in the manner of compensation capacitor 1 and compensation capacitor 2. The vacuum circuit breaker unit includes multiple groups of vacuum circuit breakers, which are sequentially marked and sorted in the manner of vacuum circuit breaker 1 and vacuum circuit breaker 2. The PLC control unit is used to control multiple groups of vacuum circuit breakers to realize automatic timely and appropriate switching of multiple groups of compensation capacitors for compensation, so that the real-time change of the load always runs at full power; The power interface of the variable frequency induction melting furnace unit is electrically connected to the input end of the variable frequency power module, the input end of the variable frequency power module is electrically connected to the output end of the rectifier voltage module, and the input end of the rectifier voltage module is electrically connected to the external power grid; The output signal of the PLC control unit is connected to the signal input of the vacuum circuit breaker unit, the output signal of the vacuum circuit breaker unit is connected to the signal input of the capacitance compensation unit, the input of the capacitance compensation unit is electrically connected to the output of the capacitance monitoring module, and the capacitance monitoring module is used to collect voltage and current parameters of multiple groups of compensation capacitors in the capacitance compensation unit in real time; An induction coil unit is arranged inside the variable frequency induction melting furnace unit. The induction coil unit is applied to the induction melting furnace coil on the variable frequency induction melting furnace. An upper water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged above the equipment of the induction coil unit. A lower water-cooling coil module wound on the variable frequency induction melting furnace unit is arranged below the equipment of the induction coil unit. A temperature sensing module is also arranged in the permanent layer of the variable frequency induction melting furnace unit. The temperature sensing module is used to provide temperature detection of the entire area near the induction coil unit.

2. A variable frequency super-large alloy induction melting furnace device according to claim 1, characterized in that: The rectifier voltage module is a 24-pulse large rectifier transformer.

3. The variable frequency super-large alloy induction melting furnace device according to claim 1 is characterized in that: The main technical parameters of the variable frequency super-large alloy induction melting furnace device are as follows: Incoming line voltage: 1900V Incoming current: 3343A Output voltage: 6600V Output power: 40000kW Operating frequency: 150Hz Furnace capacity: 90~100t.

4. The variable frequency super-large alloy induction melting furnace device according to claim 1 is characterized in that: The multiple groups of vacuum circuit breakers in the vacuum circuit breaker unit and the multiple groups of compensation capacitors in the capacitance compensation unit are controlled in a one-to-one correspondence. The multiple groups of compensation capacitors in the capacitance compensation unit are switched in three gears according to the switching amount. The three-gear switching compensation capacitors are divided into three gears: high, medium and low.

5. The variable frequency super-large alloy induction melting furnace device according to claim 1 is characterized in that: The induction coil unit comprises an induction coil module 1 and an induction coil module 2, and the induction coil module 1 and the induction coil module 2 are respectively wound on the equipment of the variable frequency induction melting furnace 1 and the variable frequency induction melting furnace 2.

6. A variable frequency super-large alloy induction melting furnace device according to claim 5, characterized in that: When the induction coil module 1 and the induction coil module 2 are being wound, an inductance elimination module is provided on the induction coil module 1 and the induction coil module 2. The inductance elimination module is used to eliminate the superimposed virtual voltage between the induction coil and the upper and lower water-cooling coils, thereby avoiding discharge and sparking problems between the induction coil and the water-cooling coil.

7. The variable frequency super-large alloy induction melting furnace device according to claim 1 is characterized in that: The equipment of the variable frequency induction melting furnace 1 and the variable frequency induction melting furnace 2 are both equipped with a water cooling device unit and a hydraulic device unit. The water cooling device unit is used to provide a water cooling function, and the hydraulic device unit is used to monitor the operating status of the equipment.

8. The variable frequency super-large alloy induction melting furnace device according to claim 1, characterized in that: The temperature sensing module is a Raman distributed optical fiber sensor, which is embedded in a permanent layer close to the induction coil unit and uses the transmission characteristics of light waves in optical fibers to measure the temperature field distribution near the induction coil unit in real time.

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