Induction Furnace Power Supply with DC-Link Energy Buffering
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Solution Overview
Problem
Existing metal melting and heating plants relying on induction furnaces are disadvantaged by the need for constant connection to the mains power network, leading to high energy costs, vulnerability to blackouts, and inefficiencies in energy use, particularly in areas with expensive or unreliable power supplies.
Innovation Solution
Incorporating an alternative energy source independent of the mains power network, such as renewable or non-renewable sources, connected to the induction furnace via a DC-Link system, allowing flexible energy supply and accumulation, managed by a control unit to optimize energy use based on cost and availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plant is continuously connected to the mains power network to ensure sufficient energy supply, then the reliability of energy supply is improved, but the energy cost increases and the plant becomes vulnerable to blackouts
Solution Approach 1:
The patent applies preliminary action by accumulating electrical energy in advance using capacitors or batteries during periods when mains power is available and cost-effective. This stored energy is then utilized during blackouts or expensive periods, eliminating the need for continuous connection to the mains network while ensuring reliable operation.
Solution Approach 2:
The system changes the parameter of energy supply source dynamically, switching between mains power, stored electrical energy, and alternative energy sources based on availability and cost. This allows the plant to operate independently from the mains network while optimizing energy costs and reliability.
2Use of energy by moving object
If the plant concentrates production during periods of lower energy cost, then the energy cost decreases, but the productivity and delivery timing are affected
Solution Approach 1:
The patent enables continuous production by providing multiple energy supply sources including stored energy and alternative energy sources. This eliminates the need to concentrate production during specific low-cost periods, allowing uninterrupted operation while maintaining cost efficiency through intelligent energy management.
3Use of energy by moving object
If the plant is disconnected from the mains power network to reduce energy costs, then the energy cost decreases, but the reliability of energy supply deteriorates
Solution Approach 1:
The patent introduces intermediate energy storage systems (capacitors, batteries) and alternative energy sources as mediators between the plant and the mains power network. These intermediaries ensure continuous energy supply when disconnected from the mains, maintaining reliability while enabling cost reduction through selective disconnection.
4Device complexity
If a traditional mains power network is used, then the device complexity is low, but the vulnerability to blackouts and high energy costs increase
Solution Approach 1:
The patent segments the power supply system into multiple independent sources: mains power network, energy storage systems, and alternative energy sources. This segmentation allows the plant to operate with reduced complexity by disconnecting from the mains network while maintaining reliability through the segmented alternative sources.
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
Enables partial or complete independence from the mains power network, reducing energy costs, minimizing shutdown risks, and ensuring continuous operation, including during blackouts, while potentially lowering CO2 emissions.
Implementation Method 1
induction furnaces are used in metallurgy to melt or heat metal materials according to the principle of electromagnetic induction
Implementation Method 2
Induction heating is widely used in the metal industry
Implementation Method 3
at least one rectifier located downstream of the transformer to transform the alternating current at exit from the transformer into direct current
Implementation Method 4
at least one converter located downstream of the rectifier to transform the direct current at exit from the rectifier into alternating current
Data Source
AI summary
Embodiments concern a plant for melting and/or heating metal material and a corresponding method to supply electrical energy. The plant comprises at least one induction furnace (11) and means (12) for supplying electrical energy to the induction furnace 11), wherein the electric power supply means (12) comprise at least one transformer (13) connected to an alternating current mains power network (14), at least one rectifier (15) located downstream of the transformer (13), at least one converter (16) located downstream of the rectifier device (15), and at least one coil (17) for melting and/or heating metal material.