Induction Heating Generator

  • Induction Heating Generator
  • Induction Heating Generator
  • Induction Heating Generator

Induction heating generator,induction generator,induction heating furnace,induction heating unit

General introduction of DW-MF series:
All DW-MF heating systems are consisted of three main parts:
>DW-MF series medium frequency generator;
>compensating capacitor or medium frequency transformer;
>heating furnace or induction coil.
DW-MF series medium frequency generator is universal, its frequency ranges from 1KHZ to 20KHZ, when working, generators can trace the frequency automatically. We can supply DW-MF series power range from 15KW to 300KW, main models are DW-MF-15, DW-MF-25, DW-MF-35, DW-MF-45, DW-MF-70, DW-MF-90, DW-MF-110, DW-MF-160, and DW-MF-300.
Heating furnace or induction coil and compensating capacitor or medium frequency transformer are designed and matched according to the application details. So every DW-MF series heating system is designed specially to optimize the system to satisfy the frequency requirements or heating depth requirements or other desires. For all the metal whether it is magnetic sensitive or not, for almost all the situation, DW-MF series heating system can be designed with best power output.
Frequency range (1-20KHZ) of DW-MF series is suitable for the penetrating heat of shafts and rods and other type metal parts for heat treatment or forging or metal melting. DW-MF forging furnace and DW-MF melting furnace are the two most widely used heating system now. except thest two , DW-MF series are also used widely for heat for matching, tube heating and so on.
Main combinations of the DW-MF medium frequency heating machine:
As said above, parallel oscillating circult is applied in our DW-MF medium frequency heating systems. There are two kinds of combinations usually used now according to the different applications:
Combination 1: M.F. generator + compensating capacitor + coil

This is the most popular combination widely used now, for example, the M.F. forging furnace and melting furnace. Machine of this kind is simple, low cost, high efficiency.
In this combination, the coil is large or long, usually 3 to 10 meters long copper tube is needed turn the coil. There is 550V high voltage directly between the coil and is not safe. So to ensure the safety of the operator, the coil must be insulated properly.
Combination 2: generator + ( compensating capacitor + transformer) + coil

This combination is also used widely, for example, melting furnace in vacuum and medium frequency quenching.
In this combination, different output current and voltage can achieved through the changing of the ratio of the transformer to fit different applications.
In this combination, coil is isolated from the main circuit, so the coil is safe and need low insulation or no insulation.
Due to the adding of the transformer, the size and the cost of the whole heating system are raised, at the same time, transformer increases the energy consumption. The lower the frequency, the bigger the transformer size , the higher the cost, the more the engergy consumption is .
The control theory of the generator and feature:
In DW-MF series generator, parallel oscillating circuit is used, after oscillating circuit, power is output directly to the induction coil.
When using DW-MF transformer, oscillating have two different connecting ways, one is parallel with the primary coil of the transformer, second is parallel with the secondary coil of the transformer.
Inside the DW-MF generators, IGBT module and current inverting control technology has been used, that is the soft and dual control and inverting technology on the basis of parallel oscillating circult. In this technology, output power and frequency can be controlled and adjusted sparetely, IGBT module and soft switching control technology are used in the high frequency switching circuit is applied to achieve high speed and accurate soft switching control. The adption of new technologies not only improves the quality and reliablility of the machine. But also solve the technology problem on large power induction heating machine and makes it possible to work 100% duty cycle.
Model explanation: DW-MF-XXX AB
>DW-MF--- Product series( medium frequency generator series)
>XXX-- Rated input power
>A -- Additional function A -- with timer function B—split type
Generator specifications:

Model

DW-MF-15

DW-MF-25

DW-MF-35

DW-MF-45

DW-MF-70

DW-MF-90

DW-MF-110

DW-MF-160

DW-MF-300

Max Input
power

15KW

25KW

35KW

45KW

70KW

90KW

110KW

160KW

300KW

Max Input current

23A

36A

51A

68A

105A

135A

170A

240A

480A

Output current

3-22A

5-45A

10-70A

15-95A

20-130A

25-170A

30-200A

30-320A

30-450A

output voltage

70-550V

Input
voltage

3phase 380V ±20% 50 or 60HZ or according customer’s requirement.

Frequency

1KHZ – 20KHZ according customer’s workpiece require.

Duty cycle

100% 24hours continuous working

Generator Net weight

26

28

35

47

75

82

95

125

240

Generator Size
LxWx H

470x270x450mm

520x270x450mm

650x350x550mm

750x400x870mm

820x500x870mm

560x560x1750mm

Timer

Heating time: 0.1-99.9seconds retaining time: 0.1-99.9seconds

Front panel

LCD, display frequency, power, time etc.

Whole systems water flow

≥0.2Mpa ≥6L/Min

≥0.3Mpa ≥10L/Min

≥0.3Mpa ≥20L/Min

≥0.3Mpa ≥30L/Min

Power
supply
water flow

≥0.2Mpa ≥3L/Min

≥0.2Mpa ≥4L/Min

≥0.2Mpa ≥6L/Min

≥0.2Mpa ≥10L/Min

Water way

1 water inlet, 1 water outlet

1 water inlet, 3 water outlet

Max
water temperature

≤45℃

Generator main characteristics:
>With IGBT power component and current inverting technology, and parallel oscillating circuit is used.
> wide frequency range from 1KHZ to 20KHZ, it is easy to match the machine according to the parts and heating desire.
> due to the parallel oscillating structure, it is easy to get the best matching of the machine to get high heating efficiency and full power output of generator.
> due to the high technologies of inverting control, soft and accurate switching control is realized to assure the high reliability and low repair of the machine.
> small size , compared with SCR controlled machine, only 1/10 working space is needed, greatly reduce occupation space.
> High efficiency and energy saving:,a high power factor and power efficiency within the scope of full power.
> With wide frequency range from 1-20KHZ automatic tracking ability, no need adjustment at scene.
> 100% duty cycle , 24hours continuous working ability at maximum power.
> Constant output voltage or power control modes are alternative;
> Full display of output power, output frequency, output voltage and current。
> simple operation: operation can be learned in a one minute.
> simple installation: connect the machine to 3phase 380VAC and cooling water only.
> timer can be chosen to preset and adjusted the heating time, heating power, retaining time, retaining power respectively to control the heating curve and heating temperature.
Advantages and applications of models with timer function:

>heating power, retaining power, heating time, retaining time can be preset and adjusted, this makes it possible to control the heating curve and heating temperature.
> it is suitable to use in the repeated heating or high speed heating of small parts.
> by presetting the timer and the power of the generator, retaining can be realized to a certain extent.
Main application:
>Medium frequency machines are usually used in the penetration heating occations, for example,
>rod heating for forging
>rod end heating
>melting of almost all kinds of metals
>heating of stators or rotors for fitting
>heating of tube end for extrusion
>heating of moulds
>deep quenching of shafts and gears
>tempering or preheating of weld joint and so on .
The composing of the DW-MF induction melting furnace:

> DW-MF induction heating generator.
> compensating capacitor
> melting furnace
Options:

>infrared sensor,
> temperature controller.
> hydraulic pump.
> water cooling systems.
> others.
induction melting furnace
Three types of melting furnaces can be selected according to the way of pouring out, they are tilting furnace, push-up furnace and stationary furnace. According to the method of tilting, tilting furnace is divided into threee kinds: manual tilting furnace, electrical tilting furnace and hydraulic tilting furnace.Main features of DW-MF melting furnace:

>DW-MF melting furnace can be used for the melting of steel, stainless steel, brass, aluminum, gold,silver and so on.
> because of the stirring effect which caused by the magnetic force, the melting pool can be stirred during the melting course to ease the floating of the flux and oxides to produce high quality casting parts.
> wide frequency range from 1KHZ to 20KHZ, working frequency can be designed by changing the coil and compensating capacitor according to the melting material, quantity, stirring effect desire, working noise, melting efficiency and other factors.
> compared with SCR medium frequency furnace, it can save energy at least 20% and up.
> small and light, a lot of modes can be selected to melt different amount of matals. Not only it is suitable for the factory, but also suitable for the colleage and researching companies to use.
> 24hours non-stop melting ability.
> it’s easy to change melting furnace for different capacity,different material, different way of pouring out, to suitable for all kinds of requirements.
Main models and melting abilities:
The table below lists the main models and recommended maximum melting abilities. About 50 to 60 minutes are needed to finish one melting process at cool status of the furnace, at hot status of the furnace, only 20 to 30 minutes are needed.

Model

Max input power

Maximum melting capacity

Iron、 steel 、stainless steel

Gold、silver、copper、bronze

aluminum、aluminum alloy

DW-MF-15 induction melting furnace

15KW

3KG

10KG

3KG

DW-MF-25 induction melting furnace

25KW

5KG

20KG

5KG

DW-MF-35 induction melting furnace

35KW

10KG

30KG

10KG

DW-MF-45 induction melting furnace

45KW

18KG

50KG

18KG

DW-MF-70 induction melting furnace

70KW

25KG

100KG

25KG

DW-MF-90 induction melting furnace

90KW

40KG

120KG

40KG

DW-MF-110 induction melting furnace

110KW

50KG

150KG

50KG

DW-MF-160 induction melting furnace

160KW

100KG

250KG

100KG

DW-MF-300 induction melting furnace

300KW

200KG

500KG

200KG

 














The composing of the DW-MF induction forging furnace:
> DW-MF induction heating generator.
> compensating capacitor
> heating coil and guide rail and coil cover.
> pneumatic rod feeder.
> working tabke and stander.
Options:

> infrared sensor,
> temperature controller.
> automatic rod picking and feeding systems
> hydraulic pump.
> water cooling systems.
> others.
fully auto foring rod furnace
Main Applications:
DW-MF forging furnace is used to heating rod with diameter from Φ15 to 80mm or quadrates or other shape stuff in the shaping of screws, nuts, valves, locks and other metal parts, the material can be steel ,stainless steel, copper, brass, aluminum and so on, that used for whole heating, partial heating or middle part heating.
Typical applications:
Whole rod heating、manual feed end heating、Auto-feed end heating 、end or middle part heating
Main features of the DW-MF foging furnace:

>Wide frequency range from 1KHZ to 20KHZ, frequency can be designed to satisfy different size of the heated workpieces. And the actual frequency is depended on the coil and the compensating capacitor designed. When heating small rods, frequency can be designed higher to achieve high heating efficiency, but to heat the thick rods, lower frequency is needed to maintain heat penetrating.
> The heating coil can be 500mm to 1 meter and up, 5 to 10 pieces are heated at the same time to make sure the penetrating effect. Coil size is depended on the rod size, and coils can be easily changed.
> In the continuous heating process, the load inside the coil is stable, thus to overcome the great heating power change caused by the great change of the load during the heating course from cool to 1100℃, the actual power can reach more than 85% of the rated power of the machine.
> Pneumatic rod feeding system is applied, only the heating power and the feeding speed are adjusted to send the rod out continuously by step. It is very convenient to coperate.
> Even when heating non-ferrous metals like copper or aluminum, the actual power can also reach more than 85% of the rated power of the machine by design the coil properly and match the compensating capacitor correctly. 3.5KG copper or brass can be heated to 700℃ per kilowatt in an hour.
> compared with SCR medium frequency furnace, it is small size, easy maintenance, it can save energy by 15-20%.
Main models and heating ability:

Models

Max input power

Recommend application

Heating ability of normal material

Steel or stainless steel to 1100℃

Copper or brass to 700℃

DW-MF-35 induction forging furnace

35KW

Φ15-30 rod heating

1.25KG/min

1.75KG/min

DW-MF-45 induction forging furnace

45KW

1.67KG/min

2.33KG/min

DW-MF-70 induction forging furnace

70KW

Φ15-50 rod heating

2.5KG/min

3.5KG/min

DW-MF-90 induction forging furnace

90KW

Φ25-50 rod heating

3.33KG/min

4.67KG/min

DW-MF-110 induction forging furnace

110KW

4.17KG/min

5.83KG/min

DW-MF-160 induction forging furnace

160KW

Φ50 up rod heating

5.83KG/min

DW-MF-300 induction forging furnace

300KW

Φ50-80 rod heating

11.25KG/min

DW-MF heating furnace with infrared temperature controller
Used for materials such as copper and aluminum which have small gap between forging temperature and melting point.and also used for the occasion when forging temperature is needed to be accurately controlled.
Advantages:

>by detecting the rod temperature at the outlet of the induction coil, the heating power is controlled by the temperature controller device, such to control the temperature of the rod.
> melting of rods inside the induction coil will not happen any more by the using of infrared sensor and temperature control device. The operating is eased, at the same time, repair of the induction coil is decreased greatly.
> it is especially important and necessary to use infrared sensor when heating brass and aluminum rods of which the forging temperature and melting point is very near. The forging temperature of brass is about 700℃ and melting point about 900℃, the forging temperature of aluminum is about 450-500℃ and melting point about 660℃, in the continuously heating and feeding process, it is likely to happen that the rods melt inside the induction coil due to to careless of operator,. To install the infrared sensor is the only way to solve this problem.
Rod heating furnace with auto-feed system
Used for the automatically heating of steel, brass, aluminum and other metal rods.
Characteristics:

> whole processes including the rod picking up, rod selecting, rod pushing and rod sending out, heating and temperature controlling are all automatically controlled by PLC device.
> a wide range of rod size from Φ20 to Φ60 and length from 50 to 250mm.
> the temperature of the rod can be exactly controlled to achieve high quality of the parts.