High-efficiency low-consumption large-tonnage smelting inductor

Abstract

The application discloses a high-efficiency low-consumption large-tonnage smelting inductor, and relates to the technical field of smelting inductors. The smelting inductor comprises an inductor body, a double-sided wire inlet structure arranged on the inductor body, and an inductive winding arranged in the inductor body. In the initial loading stage and the low-liquid-level stage in the early smelting stage, the first inductive coil and the second inductive coil are alternately arranged in space and jointly cover the whole axial height of the inductor body, and the two always maintain a synchronous power-on working state. Therefore, the originally wasted magnetic field energy in the low-liquid-level stage can be fully utilized, the electromagnetic energy conversion efficiency is greatly improved, and the ton-steel smelting power consumption is significantly reduced. Meanwhile, the integrated structure formed by the cross winding enables the first inductive coil and the second inductive coil to mutually restrict and cooperatively bear under the action of electromagnetic force and thermal stress, thereby effectively eliminating the local deformation and displacement problems of the traditional segmented independent coils caused by uneven stress.

Description

Technical Field

[0001] This invention relates to the field of melting inductor technology, and in particular to a high-efficiency, low-consumption, large-tonnage melting inductor. Background Technology

[0002] Large-tonnage induction inductors are the core heating components of medium-frequency induction melting furnaces, widely used in metallurgical smelting fields such as steel and non-ferrous metals. They play a crucial role in converting electromagnetic energy into the heat energy of metal smelting, and their performance directly determines smelting efficiency, energy consumption costs, and equipment operational stability. To meet the process requirements of large-tonnage melting furnaces for high-current delivery and high-power operation, the industry currently widely adopts a double-sided symmetrical inductor structure. This structure relies on two independent windings to achieve electromagnetic induction heating, adapting to the large-capacity smelting conditions of large-tonnage furnaces and meeting the basic heating requirements of conventional batch metallurgical production. Traditional double-sided inductors, to adapt to large-size furnace structures, typically have a dividing structure in the middle of the windings, splitting the entire winding into two independent induction units. Each winding corresponds to one of the double-sided inductor ports, with the turns ratio, impedance parameters, and winding specifications remaining highly consistent to achieve balanced current delivery on both sides.

[0003] Because existing inductor windings use a segmented design with intermediate separation and independent upper and lower sections, forming two completely separate inductor units, the equipment operates in a segmented coupling mode. During the initial charging and early smelting stages when the molten steel level is low, only the lower inductor unit can contact the scrap steel and molten steel to generate effective electromagnetic coupling, while the upper inductor unit remains completely suspended. A large amount of magnetic field energy cannot be utilized, resulting in extremely low electromagnetic energy conversion efficiency and significant energy waste, leading to persistently high power consumption per ton of steel smelting. Simultaneously, the independent upper and lower segmented coil structure results in extremely uneven force distribution. Under long-term exposure to alternating electromagnetic forces and high-temperature thermal stress, it is prone to localized deformation and displacement problems. This not only further exacerbates leakage flux loss but also shortens the inductor's lifespan, leading to a high equipment failure rate. This fails to meet the long-term, continuous, and high-load industrial production requirements of large-tonnage smelting furnaces. Therefore, developing a high-efficiency, low-consumption, and structurally stable large-tonnage smelting inductor has become a pressing technical challenge in the metallurgical smelting field. Summary of the Invention

[0004] This invention provides a high-efficiency, low-consumption, large-tonnage smelting inductor that can solve the problem in the prior art where, in the early stages of charging and the early stages of smelting when the molten steel level is low, only the lower inductor unit can contact the scrap steel and molten steel and generate effective electromagnetic coupling, while the upper inductor unit is completely suspended and idle, and a large amount of magnetic field energy cannot be utilized.

[0005] A high-efficiency, low-consumption, high-tonnage smelting inductor includes an inductor body, a double-ended inductor structure mounted on the inductor body, and an inductor winding disposed inside the inductor body. The inductor winding includes a first inductor coil and a second inductor coil, which are wound axially in a cross-shaped manner to form an integrated structure. Both the first and second inductor coils are electrically connected to the double-ended inductor structure, enabling the first and second inductor coils to synchronously achieve electromagnetic coupling with the material inside the furnace throughout the entire smelting process.

[0006] The present invention provides a high-efficiency, low-consumption, high-tonnage smelting inductor, which, compared with the prior art, has the following beneficial effects, but is not limited to: This high-efficiency, low-consumption, large-tonnage smelting inductor, during the initial charging and early smelting stages when the molten steel level is low, utilizes the magnetic field energy that would otherwise be wasted at low liquid levels. This significantly improves electromagnetic energy conversion efficiency and reduces power consumption per ton of steel smelting. Furthermore, the integrated structure formed by the cross-winding allows the first and second inductor coils to mutually restrain and cooperate under electromagnetic force and thermal stress. This breaks away from the traditional dual-ended inductor structure that isolates and independently powers the upper and lower coils, effectively eliminating the local deformation and displacement problems caused by uneven stress in traditional segmented independent coils, and significantly enhancing the overall structural stability of the inductor.

[0007] Furthermore, the first induction coil and the second induction coil are arranged alternately in a spiral shape along the axial direction of the sensor body, and adjacent turns of the coil come from different induction coils.

[0008] Furthermore, the dual-inlet structure includes a first inlet end and a second inlet end, wherein the first inlet end is connected to the first induction coil and the second inlet end is connected to the second induction coil.

[0009] Furthermore, the first and second induction coils have a flat tube shape, with a width-to-height ratio of 1.5:1 to 4:1.

[0010] Furthermore, the substrates of the first and second induction coils are copper-silver alloys or copper-chromium-zirconium alloys.

[0011] Furthermore, an insulating support assembly is provided on the outer side of the induction winding. The insulating support assembly is spaced axially around the outer periphery of the induction winding. The insulating support assembly includes a plurality of insulating pillars evenly distributed circumferentially. A guide groove is opened on the side of the insulating pillar facing the induction winding. An insulating buffer pad is provided at the bottom of the guide groove. The insulating buffer pad is sandwiched between the guide groove and the induction coil. The insulating pillar is connected to the sensor body through a fixing member.

[0012] Furthermore, a first magnetic yoke assembly and a second magnetic yoke assembly are provided on the outer side of the induction winding. The first magnetic yoke assembly and the second magnetic yoke assembly are arranged alternately along the axial direction on the outer periphery of the induction winding. Both the first magnetic yoke assembly and the second magnetic yoke assembly are connected to the sensor body through a fixing member.

[0013] Furthermore, the first magnetic yoke assembly includes a first silicon steel sheet group, with a first stainless steel plate sandwiched between the two sides of the first silicon steel sheet group. One end of the first stainless steel plate is bent inward to cover the first silicon steel sheet group. One end of the first silicon steel sheet group is recessed inward near the bend of the first stainless steel plate to form a recessed portion. The recessed portion and the bend of the first stainless steel plate form a vertically penetrating air duct. The end of the first silicon steel sheet group away from the bend of the first stainless steel plate protrudes outward to form a first protruding portion. The first protruding portion is in contact with the outer periphery of the induction winding.

[0014] Furthermore, the second magnetic yoke assembly includes a second silicon steel sheet group, with a second stainless steel plate sandwiched between the two sides of the second silicon steel sheet group. Each side of the second stainless steel plate is equipped with a water-cooling pipe. The end of the second silicon steel sheet group facing the induction winding protrudes outward to form a second protrusion, which is in contact with the outer periphery of the induction winding.

[0015] Furthermore, a heat-conducting plate that fits into the sensor body is connected between the first magnetic yoke assembly and the second magnetic yoke assembly. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a high-efficiency, low-consumption, large-tonnage smelting inductor according to an embodiment of the present invention; Figure 2 for Figure 1 A schematic diagram of the structure where the induction coils of the induction winding are separated; Figure 3 for Figure 1 A schematic diagram of the combined structure of the induction coils in the intermediate induction winding; Figure 4 for Figure 1 A schematic diagram of the structure of the first magnetic yoke assembly; Figure 5 for Figure 1 A schematic diagram of the structure of the second magnetic yoke assembly; Figure 6 for Figure 1 A schematic diagram of the structure of the insulation support assembly.

[0017] Explanation of reference numerals in the attached figures: 1. Sensor body; 2. Dual-sided inlet structure; 3. Induction winding; 4. First yoke assembly; 5. Second yoke assembly; 6. Insulation support assembly; 7. Fixing component; 8. Fastening heat-conducting plate; 21. First inlet end; 22. Second inlet end; 31. First induction coil; 32. Second induction coil; 41. First stainless steel plate; 42. First silicon steel sheet assembly; 43. Recess; 44. Air duct; 45. First protrusion; 51. Second stainless steel plate; 52. Second silicon steel sheet assembly; 53. Water cooling pipeline; 54. Second protrusion; 61. Insulation support column; 62. Guide groove; 63. Insulation buffer pad. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings showing multiple embodiments according to this application. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments described in this application without creative effort will fall within the scope of protection of this application.

[0019] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising," "including," "having," "containing," etc., in the description, claims, and accompanying drawings of this application are open-ended terms. Therefore, "comprising," "including," or "having" refers to, for example, a method or apparatus having one or more steps or elements, but is not limited to having only these one or more elements. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0020] In the description of this invention, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0021] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0022] It should be emphasized that when the term "comprising / including" is used in this specification, it is used to explicitly indicate the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, parts, or groups of features, integers, steps, or parts.

[0023] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0024] like Figure 1-3 As shown in the figure, an embodiment of the present invention provides a high-efficiency, low-consumption, high-tonnage smelting inductor, including an inductor body 1, a double-sided inlet structure 2 disposed on the inductor body 1, and an inductor winding 3 disposed inside the inductor body 1; the inductor winding 3 includes a first inductor coil 31 and a second inductor coil 32, the first inductor coil 31 and the second inductor coil 32 are wound axially to form an integrated structure, and both the first inductor coil 31 and the second inductor coil 32 are electrically connected to the double-sided inlet structure 2, so that the first inductor coil 31 and the second inductor coil 32 can synchronously achieve electromagnetic coupling with the material in the furnace throughout the entire smelting stage.

[0025] In this embodiment, during the initial charging stage and the early smelting stage when the molten steel level is low, the first induction coil 31 and the second induction coil 32 are arranged alternately in space, jointly covering the entire axial height of the inductor body 1, and both are always kept in a synchronous energized working state. Therefore, regardless of the molten steel level, there are induction units from both sets of coils that form effective electromagnetic coupling with the scrap steel or molten steel. This eliminates the phenomenon of the upper induction unit being completely suspended in the traditional structure, allowing the magnetic field energy that was wasted in the low liquid level stage to be fully utilized, greatly improving the electromagnetic energy conversion efficiency and significantly reducing the power consumption per ton of steel smelting. At the same time, the integrated structure formed by cross-winding allows the first induction coil 31 and the second induction coil 32 to restrain each other and cooperate in bearing under the action of electromagnetic force and thermal stress. This breaks the traditional structure of dual-sided inductor that isolates the upper and lower coils in sections and supplies power independently. It effectively eliminates the local deformation and displacement problems caused by uneven force on the traditional segmented independent coils, significantly enhances the overall structural stability of the inductor, and extends the continuous operating life of the equipment under high load conditions.

[0026] Specifically, the integrated cross-wound winding structure allows the magnetic fields of the two sets of coils to superimpose and focus efficiently, ensuring that no induction unit is idle throughout the entire melting process. This solves the problem of magnetic field energy waste caused by segmented coupling in traditional designs, significantly improving electromagnetic induction efficiency and reducing ineffective energy consumption at the source. The integrated cross-wound structure avoids the technical problem of uneven force distribution in traditional independent upper and lower coils, greatly improving the overall resistance of the equipment to electromagnetic forces and thermal stress. This effectively reduces deformation losses during long-term high-load use and significantly extends the actual industrial service life of the inductor.

[0027] Among them, the core design of the high-efficiency, low-consumption, high-tonnage smelting inductor adapted to a 90-ton metal smelting furnace is as follows: the two independent sets of induction windings of the traditional double-sided wire-in-line structure are cross-wound and integrated, eliminating the original middle separation structure, so that the induction windings form an integrated cross-wound structure; the matching induction copper tube adopts a customized design, adjusting the tube shape to a flat optimized structure, optimizing the copper alloy ratio in the base material composition to improve conductivity, and thickening the wall according to the stress characteristics of cross-wound and electromagnetic transmission requirements, so as to accurately adapt to the high current and high load industrial conditions of the 90-ton smelting furnace.

[0028] When applied to a 90-ton smelting furnace, this inductor achieves effective electromagnetic coupling with the scrap steel during the initial charging stage (when the molten steel level is 30% of the furnace volume), with no inductor units remaining idle. During the level rise stage (when the molten steel level is 30%-80% of the furnace volume) and the full-level stage (when the molten steel level is 80%-100% of the furnace volume), the magnetic fields generated by the two sets of coils remain superimposed and focused, reducing leakage magnetic loss by more than 40% compared to traditional inductors. Under the same furnace construction process, scrap steel recovery rate, and tapping temperature, the power consumption per ton of steel is reduced by 40 kWh, the smelting speed is increased by 12%, and the equipment showed no significant deformation after 9 months of continuous high-load operation, demonstrating significantly better structural stability than traditional inductors.

[0029] like Figure 2 and Figure 3 As shown, the first induction coil 31 and the second induction coil 32 are arranged in a spiral alternation along the axial direction of the sensor body 1, and adjacent turns of the coil come from different induction coils.

[0030] In this embodiment, the first induction coil 31 and the second induction coil 32 are arranged in a spiral alternation to form a uniformly interwoven and tightly coupled electromagnetic field distribution structure along the entire axial height of the sensor body 1. The magnetic fields of adjacent coils are superimposed and enhanced due to the different induction coils, thus eliminating the weak magnetic field area or transition discontinuity between the upper and lower induction units in the traditional segmented structure.

[0031] Specifically, during the initial charging stage and the early smelting stage when the molten steel level is low, the turns of the two sets of coils are alternately interwoven in the axial direction. Even if the liquid level only covers part of the axial height, the height range still includes the turns from the first induction coil 31 and the second induction coil 32. This allows the two sets of induction units corresponding to the double-sided induction structure 2 to generate effective electromagnetic coupling with scrap steel or molten steel under any liquid level conditions, minimizing the waste of magnetic field energy caused by the idle upper induction unit in the traditional structure. At the same time, the alternating structure of adjacent turns from different induction coils allows the radial and axial forces generated by the first induction coil 31 and the second induction coil 32 under the action of electromagnetic force to cancel each other out and support each other, forming a self-balancing force system. This significantly reduces the risk of deformation of the coils during long-term high-load operation and further extends the service life of the inductor, thereby reducing the power consumption per ton of steel smelting and improving smelting efficiency.

[0032] like Figure 1 and Figure 2 As shown, the dual-inlet structure 2 includes a first inlet end 21 and a second inlet end 22. The first inlet end 21 is connected to the first induction coil 31, and the second inlet end 22 is connected to the second induction coil 32.

[0033] In this embodiment, by connecting the first input terminal 21 to the first induction coil 31 and the second input terminal 22 to the second induction coil 32 in a one-to-one correspondence, an electrical architecture with dual independent power supply and dual collaborative operation is constructed based on the cross-wound integrated structure. This connection method enables the first induction coil 31 and the second induction coil 32 to obtain independent current input paths, ensuring that the two sets of induction coils are always in a synchronously energized and independently controlled working state throughout the entire melting stage, avoiding the problem of uneven current distribution or phase delay caused by sharing input terminals in the traditional segmented structure.

[0034] Specifically, since the first input terminal 21 supplies power only to the first induction coil 31 and the second input terminal 22 supplies power only to the second induction coil 32, although the distribution of the two sets of coils in the electromagnetic field space is in an alternating and intertwined state, they remain completely independent in the electrical circuit. This "electrically independent, spatially intertwined" design not only ensures the current load balance of the double-sided input structure 2 and reduces the risk of overheating caused by current concentration at the single-sided input terminal, but also enables the first induction coil 31 and the second induction coil 32 to independently generate alternating magnetic fields and achieve efficient superposition and fusion of magnetic fields based on the axial alternating arrangement.

[0035] like Figure 2 and Figure 3 As shown, the first induction coil 31 and the second induction coil 32 have a flat tube shape, and the aspect ratio of their cross-sections ranges from 1.5:1 to 4:1.

[0036] In this embodiment, compared with the traditional round tube structure, the flat structure has a larger surface area to volume ratio under the same conductor cross-sectional area, which significantly enhances the heat dissipation capacity of the coil surface and effectively reduces the temperature rise of the first induction coil 31 and the second induction coil 32 under high current conditions, avoiding insulation aging and copper tube softening problems caused by local overheating. At the same time, the flat structure, combined with a width-to-height ratio range of 1.5:1-4:1, allows the coil to obtain a more compact arrangement space in the radial direction when wound along the axial direction of the inductor body 1, reducing the distance between coil layers, thereby improving the electromagnetic coupling tightness between the induction winding 3 and the material in the furnace and reducing leakage magnetic loss.

[0037] like Figure 2 and Figure 3 As shown, the substrates of the first induction coil 31 and the second induction coil 32 are copper-silver alloy or copper-chromium-zirconium alloy.

[0038] In this embodiment, copper-silver alloy or copper-chromium-zirconium alloy has a higher softening temperature and creep resistance than ordinary pure copper material. Under the long-term high current and high load operation of the inductor, it can significantly resist the softening and deformation of the copper tube caused by the combined action of Joule heat generated by electromagnetic induction and alternating electromagnetic force, ensuring that the first induction coil 31 and the second induction coil 32 always maintain stable structural accuracy and inter-turn gap under the complex geometric shape of the spiral alternating arrangement.

[0039] like Figure 1 and Figure 6 As shown, an insulating support assembly 6 is provided on the outside of the induction winding 3. The insulating support assembly 6 is spaced along the axial direction on the outer periphery of the induction winding 3. The insulating support assembly 6 includes a plurality of insulating pillars 61 evenly distributed along the circumference. The side of the insulating pillar 61 facing the induction winding 3 has a guide groove 62. The bottom of the guide groove 62 is provided with an insulating buffer pad 63. The insulating buffer pad 63 is sandwiched between the guide groove 62 and the induction coil. The insulating pillar 61 is connected to the sensor body 1 through a fixing member 7.

[0040] In this embodiment, multiple insulating supports 61 evenly distributed along the circumference are used to bidirectionally limit the spirally alternating coils in both the axial and radial directions via guide grooves 62. This ensures that the first induction coil 31 and the second induction coil 32 maintain a preset inter-turn gap and alternating arrangement accuracy during the cross-winding process, avoiding inter-turn short circuits or a decrease in electromagnetic coupling performance caused by coil displacement. The insulating buffer pads 63 set at the bottom of the guide grooves 62 play an elastic buffering role under the action of alternating electromagnetic force, effectively absorbing the impact energy generated by electromagnetic vibration of the coil, reducing rigid friction and wear between the coil and the insulating supports 61, and reducing the risk of electromagnetic force damaging the coil insulation layer. The insulating supports 61 are connected to the inductor body 1 through the fasteners 7, forming a complete force transmission path from the coil to the insulating support assembly 6 and then to the inductor body 1. This allows the electromagnetic force and thermal stress borne by the cross-wound integrated structure to be evenly transmitted to the inductor body 1, eliminating the stress concentration and deformation problems caused by partial suspension or insecure fixation of the coil in traditional structures.

[0041] like Figure 1 As shown, a first magnetic yoke assembly 4 and a second magnetic yoke assembly 5 are provided on the outer side of the induction winding 3. The first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 are arranged alternately along the axial direction on the outer periphery of the induction winding 3. The first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 are both connected to the sensor body 1 through the fixing member 7.

[0042] In this embodiment, by setting a first magnetic yoke assembly 4 and a second magnetic yoke assembly 5 on the outside of the induction winding 3, and by axially staggering the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 on the outer periphery of the induction winding 3, and by connecting the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 to the sensor body 1 through the fixing member 7, a dual-type, staggered magnetic circuit guiding and shielding system is constructed for the cross-wound first induction coil 31 and the second induction coil 32. By axially staggering the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5, a structural synergy is formed with the cross-wound integrated induction winding 3, which further enhances the magnetic field focusing effect, controls the ineffective leakage magnetic field that does not act on metal smelting to a lower range, reduces energy loss from the source, and improves the overall structural stability of the equipment, providing a reliable magnetic circuit guarantee for the long-term efficient operation of the large-tonnage smelting furnace.

[0043] Specifically, the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5, which are staggered along the axial direction, form an alternating complementary magnetic yoke layout on the outer periphery of the induction winding 3. This layout can perform segmented and differentiated magnetic guidance treatment on the complex magnetic field distribution generated by the cross-wound structure, effectively suppressing the axial dissipation and radial diffusion of the magnetic field. The alternating layout of the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 creates a magnetic circuit series complementary effect in the axial direction, avoiding the magnetic saturation or magnetic blind zone that may occur in a single type of magnetic yoke at a specific axial position. This ensures that the induction winding 3 can obtain uniform and efficient magnetic shielding and magnetic field focusing effects throughout the entire axial height range. At the same time, the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 are both connected to the sensor body 1 through the fixing member 7, so that the two sets of magnetic yoke assemblies and the sensor body 1 form a rigidly connected overall structure.

[0044] like Figure 1 and Figure 4 As shown, the first magnetic yoke assembly 4 includes a first silicon steel sheet group 42, with a first stainless steel plate 41 sandwiched between the two sides of the first silicon steel sheet group 42. One end of the first stainless steel plate 41 is bent inward to cover the first silicon steel sheet group 42. One end of the first silicon steel sheet group 42 is recessed inward near the bend of the first stainless steel plate 41 to form a recessed portion 43. The recessed portion 43 and the bend of the first stainless steel plate 41 form a vertically penetrating air duct 44. The end of the first silicon steel sheet group 42 away from the bend of the first stainless steel plate 41 protrudes outward to form a first protruding portion 45. The first protruding portion 45 is attached to the outer periphery of the induction winding 3.

[0045] In this embodiment, the vertical ventilation channel 44 formed by the recess 43 and the bend of the first stainless steel plate 41 utilizes the principle of natural convection or forced ventilation to construct a through-type heat dissipation channel inside the first magnetic yoke assembly 4. This channel can promptly remove the heat generated by the first silicon steel sheet group 42 due to eddy current and hysteresis losses, preventing the magnetic permeability from decreasing or the insulation layer of the silicon steel sheet from aging and failing due to excessive temperature rise of the magnetic yoke. The first protrusion 45 is fitted to the outer periphery of the induction winding 3, forming a tight contact with zero gap between the first magnetic yoke assembly 4 and the induction winding 3. This minimizes the magnetic circuit distance from the induction winding 3 to the magnetic yoke, reduces the air gap loss in the magnetic circuit, and further enhances the magnetic field focusing effect.

[0046] Specifically, the first stainless steel plate 41 held by both sides, combined with the inwardly bent covering structure at one end, forms a three-sided enclosure and constraint for the first silicon steel sheet group 42. This effectively prevents the silicon steel sheets from loosening, misaligning, or warping at the edges under electromagnetic force, significantly improving the structural stability and fatigue resistance of the first magnetic yoke assembly 4 under long-term alternating magnetic field conditions. This allows the first magnetic yoke assembly 4 to not only closely cooperate with the cross-wound induction winding 3, but also to have the comprehensive performance of high-strength covering and fixing, efficient vertical ventilation and heat dissipation, and close magnetic conduction. This effectively reduces leakage magnetic loss and the temperature rise of the magnetic yoke itself, extending the service life of the magnetic yoke assembly and the overall inductor, and providing reliable magnetic circuit and structural dual protection for the long-term high-load operation of large-tonnage smelting furnaces.

[0047] like Figure 1 and Figure 5 As shown, the second magnetic yoke assembly 5 includes a second silicon steel sheet group 52, with a second stainless steel plate 51 sandwiched between the two sides of the second silicon steel sheet group 52. Each second stainless steel plate 51 has a water cooling pipe 53 installed on its side. The second silicon steel sheet group 52 protrudes outward from one end facing the induction winding 3 to form a second protrusion 54, which is in contact with the outer periphery of the induction winding 3.

[0048] In this embodiment, each second stainless steel plate 51 is equipped with a water-cooling pipe 53 on its side, enabling the second magnetic yoke assembly 5 to have active water-cooling heat dissipation capability. Compared with magnetic yoke structures that rely solely on natural cooling or air cooling, this can more efficiently remove the large amount of heat generated by eddy current loss and hysteresis loss in the second silicon steel sheet group 52, keeping the magnetic yoke operating temperature within a lower range. This effectively avoids the problems of decreased magnetic permeability of silicon steel sheets, aging and failure of insulation layer, and overall thermal deformation of the magnetic yoke caused by high temperature. The second protrusion 54 is set to fit against the outer periphery of the induction winding 3, forming a tight zero-gap contact between the second magnetic yoke assembly 5 and the induction winding 3. This significantly shortens the magnetic path of magnetic lines of force from the induction winding 3 into the second silicon steel sheet group 52, reduces air gap loss in the magnetic circuit, and enhances magnetic field focusing and shielding effects.

[0049] Specifically, the second stainless steel plate 51 forms a double-sided clamping protection for the second silicon steel sheet group 52, effectively suppressing the vibration and edge loosening of the silicon steel sheets under the action of alternating electromagnetic fields, and enhancing the overall structural rigidity of the second magnetic yoke assembly 5. The second magnetic yoke assembly 5 and the first magnetic yoke assembly 4 are staggered along the axial direction, and the two adopt differentiated heat dissipation schemes of air cooling and water cooling respectively, forming an alternating and complementary magnetic conduction and heat dissipation network on the outer periphery of the induction winding 3. This can give full play to their respective heat dissipation advantages and avoid heat load concentration, while achieving uniform magnetic circuit coverage throughout the entire axial direction. This allows the second magnetic yoke assembly 5 to achieve efficient magnetic conduction while closely fitting the induction winding 3, and to achieve active heat dissipation through the integrated water cooling pipeline 53. This significantly reduces the temperature rise and leakage magnetic loss of the magnetic yoke, extends the service life of the magnetic yoke assembly and the overall inductor, and provides reliable magnetic circuit and thermal management dual protection for the long-term stable operation of large-tonnage smelting furnaces under continuous high load conditions.

[0050] like Figure 1 As shown, a heat-conducting plate 8 that fits into the sensor body 1 is connected between the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5.

[0051] In this embodiment, the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5, which are arranged alternately along the axial direction, are rigidly connected in both the circumferential and axial directions by the fastening heat-conducting plate 8. This connects the originally independently installed multiple magnetic yoke assemblies into a whole force-bearing unit through the fastening heat-conducting plate 8, effectively constraining the relative displacement or vibration that may occur between the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 under the action of alternating electromagnetic force. At the same time, the electromagnetic force borne by each magnetic yoke assembly is uniformly transmitted to the sensor body 1 through the fastening heat-conducting plate 8, which significantly enhances the overall structural rigidity and electromagnetic shock resistance of the magnetic yoke system. The fastening heat-conducting plate 8 is fitted to the sensor body 1, forming a multi-point, continuous rigid connection between the magnetic yoke assembly and the sensor body 1, avoiding the stress concentration and loosening problems that may occur in traditional structures where the magnetic yoke assembly and the sensor body 1 are only connected by a fastener 7-point connection.

[0052] Specifically, the fastening heat-conducting plate 8 also serves as a heat-conducting medium, transferring the heat generated during the operation of the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5 to the inductor body 1. The large heat capacity and heat dissipation area of ​​the inductor body 1 are used to achieve auxiliary heat dissipation, improving the problem of local heat accumulation in the axially spaced area of ​​the magnetic yoke assembly, and creating a thermal balance between the first magnetic yoke assembly 4 and the second magnetic yoke assembly 5. The fastening heat-conducting plate 8 creates a structurally linked and thermally balanced overall system between the cross-wound induction winding 3, the first magnetic yoke assembly 4, the second magnetic yoke assembly 5, and the inductor body 1, further enhancing the structural stability and heat dissipation uniformity of the inductor under high-load conditions, effectively extending the service life of the equipment, and providing a reliable structural guarantee for the long-term continuous operation of large-tonnage smelting furnaces.

[0053] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A high-efficiency, low-consumption, large-tonnage smelting inductor, characterized in that, It includes a sensor body (1), a double-sided inlet structure (2) disposed on the sensor body (1), and an induction winding (3) disposed inside the sensor body (1). The induction winding (3) includes a first induction coil (31) and a second induction coil (32). The first induction coil (31) and the second induction coil (32) are wound together along the axial direction to form an integrated structure. Both the first induction coil (31) and the second induction coil (32) are electrically connected to the double-sided induction structure (2), so that the first induction coil (31) and the second induction coil (32) can synchronously achieve electromagnetic coupling with the material in the furnace during the entire melting process.

2. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 1, characterized in that, The first induction coil (31) and the second induction coil (32) are arranged in a spiral alternation along the axial direction of the sensor body (1), and adjacent turns of the coil come from different induction coils.

3. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 2, characterized in that, The dual-ended inlet structure (2) includes a first inlet end (21) and a second inlet end (22). The first inlet end (21) is connected to the first induction coil (31), and the second inlet end (22) is connected to the second induction coil (32).

4. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 1, characterized in that, The first induction coil (31) and the second induction coil (32) are flat structures with a width-to-height ratio of 1.5:1 to 4:

1.

5. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 1, characterized in that, The substrates of the first induction coil (31) and the second induction coil (32) are copper-silver alloy or copper-chromium-zirconium alloy.

6. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 1, characterized in that, An insulating support assembly (6) is provided on the outside of the induction winding (3). The insulating support assembly (6) is spaced along the axial direction on the outer periphery of the induction winding (3). The insulating support assembly (6) includes a plurality of insulating pillars (61) evenly distributed along the circumference. The insulating pillars (61) have guide grooves (62) on the side facing the induction winding (3). An insulating buffer pad (63) is provided at the bottom of the guide groove (62). The insulating buffer pad (63) is sandwiched between the guide groove (62) and the induction coil. The insulating pillars (61) are connected to the sensor body (1) through a fixing member (7).

7. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 1, characterized in that, The induction winding (3) is provided with a first magnetic yoke assembly (4) and a second magnetic yoke assembly (5) on its outer side. The first magnetic yoke assembly (4) and the second magnetic yoke assembly (5) are arranged alternately along the axial direction on the outer periphery of the induction winding (3). The first magnetic yoke assembly (4) and the second magnetic yoke assembly (5) are both connected to the sensor body (1) through a fixing member (7).

8. The high-efficiency, low-consumption, large-tonnage smelting inductor as described in claim 7, characterized in that, The first magnetic yoke assembly (4) includes a first silicon steel sheet group (42), with a first stainless steel plate (41) sandwiched between the two sides of the first silicon steel sheet group (42). One end of the first stainless steel plate (41) is bent inward to cover the first silicon steel sheet group (42). One end of the first silicon steel sheet group (42) is recessed inward near the bend of the first stainless steel plate (41) to form a recessed portion (43). The recessed portion (43) and the bend of the first stainless steel plate (41) form a vertically penetrating air duct (44). One end of the first silicon steel sheet group (42) away from the bend of the first stainless steel plate (41) protrudes outward to form a first protruding portion (45). The first protruding portion (45) is attached to the outer periphery of the induction winding (3).

9. The high-efficiency, low-consumption, high-tonnage smelting inductor as described in claim 7, characterized in that, The second magnetic yoke assembly (5) includes a second silicon steel sheet group (52), with a second stainless steel plate (51) sandwiched between the two sides of the second silicon steel sheet group (52). Each of the second stainless steel plates (51) has a water-cooling pipe (53) installed on its side. The second silicon steel sheet group (52) has a second protrusion (54) protruding outward from one end facing the induction winding (3). The second protrusion (54) is in contact with the outer periphery of the induction winding (3).

10. The high-efficiency, low-consumption, large-tonnage smelting inductor as described in claim 7, characterized in that, A heat-conducting plate (8) that fits against the sensor body (1) is connected between the first magnetic yoke assembly (4) and the second magnetic yoke assembly (5).

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