Direct Current Heating System for Semi-Finished Metal Products
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Solution Overview
Problem
Existing heating systems for semi-finished metal products, particularly special steels, are inefficient in energy usage and versatile heating, requiring substantial energy to reach desired temperatures and resulting in inefficient furnace management due to varying residence times for different steel types and geometries.
Innovation Solution
A heating system utilizing a power supply group with a thyristor power controller and input transformer to supply direct current, allowing for adaptable voltage and current output to efficiently heat semi-finished metal products through Joule effect, with a control unit and temperature sensor for optimized power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If gas heating furnaces or induction furnaces are used to heat semi-finished metal products, then the desired temperature can be reached, but substantial energy resources are required and heating efficiency is low
Solution Approach 1:
The patent replaces traditional gas heating furnaces or induction furnaces with a direct current electric heating system. The system uses DC power supply with positive and negative contacts that make direct contact with the semi-finished metal product, passing current through the product to generate heat via Joule heating. This substitution of heating method significantly improves energy efficiency while achieving the desired temperature.
Solution Approach 2:
The heating system utilizes the semi-finished metal product itself as the heating element by passing electric current directly through it. The product's own electrical resistance generates the heat required for heating, eliminating the need for external heating media like gas or induction fields. This self-heating approach reduces energy loss and improves heating efficiency.
2Adaptability or versatility
If different heating temperatures are required for different steel types and geometries, then specific heating requirements can be met, but inefficient furnace management occurs with vast sections of bogie hearth devoid of semi-finished products
Solution Approach 1:
The system employs a power supply with independently controllable positive and negative contacts that can be dynamically positioned and adjusted. The control unit independently controls the current intensity through each contact, allowing real-time adaptation to different steel types, geometries, and heating requirements. This dynamic control enables continuous optimal heating without requiring empty spaces for temperature adjustment.
Solution Approach 2:
The heating system applies different current intensities to different regions of the semi-finished metal product by independently controlling the positive and negative contacts. Each contact can be positioned and adjusted to provide localized heating appropriate to the specific geometry and material properties, ensuring optimal heating efficiency for each product without wasting furnace capacity.
3Adaptability or versatility
If semi-finished products are arranged on bogie hearth with vast sections devoid of products to adapt different transit times, then different heating temperatures can be achieved, but heating process efficiency declines
Solution Approach 1:
The direct current heating system provides continuous and uniform heating along the entire length of the semi-finished metal product as it passes between the positive and negative contacts. Both ends of the product are heated simultaneously and continuously, eliminating the need for extended transit times or empty furnace sections. This continuous heating action significantly reduces heating process time while maintaining adaptability to different product requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high efficiency and versatility in heating, reducing heating times and energy consumption, while optimizing power factor and load balance, allowing for even heating and flexible adaptation to different materials and shapes without the need for special transformers.
Implementation Method 1
supply direct current, allowing for adaptable voltage and current output to efficiently heat semi-finished metal products through Joule effect
Data Source
Figure 1
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AI summary
A heating group (1) for semi-finished metal products comprises a heating group (2) for the semi-finished metal product (10), comprising a positive contact (21) and a negative contact (22), suitable for being directly connected to the semi-finished metal product (10) to determine a current flow in the semi-finished metal product (10) during the heating step. The system (1) also comprises a power supply group (3) which is connectable to a power supply grid (4). Such a power supply group (4) comprises at least a first (31), a second (32) and a third (33) thyristor power controller. Furthermore, an input transformer (5) comprises a primary input transformer side (51) which is connectable to the power supply grid (4) and a secondary input transformer side (52) connected to the first (31), second (32), and third (33) thyristor power controllers. An adaptation apparatus (8) comprises an adaptation transformer (8') connected in cascade to the first (31), second (32), and third (33) thyristor power controllers and an AC-DC converter (8"). The AC-DC converter (8'') is suitable for converting the alternating current from the adaptation transformer (8') into direct current to be supplied between the positive contact (21) and the negative contact (22).