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Common Maintenance Tips for Intermediate-Frequency Furnace Induction Heaters
Sep 25,2020
1. Medium-Frequency Induction Heating Furnace The sensor, also known as a through-type sensor, is designed based on the length of the heating arc and the diameter of the workpiece. However, in general, medium-frequency induction heaters tend to be relatively long (referring to the axial direction of the workpiece being heated). The purpose of this longer design is to ensure that, while maintaining a constant heating cycle, the temperature difference between the surface and the core of the workpiece remains within an acceptable range.
2. Currently, Intermediate-frequency heating inductor There are basically two types of lining components: knotted linings and assembled linings.
3. Linings used for long-term connections or assemblies, when exposed to high temperatures over extended periods, will undergo changes—primarily thermal expansion, contraction, and oxidation. If not used appropriately, collisions between the heating material and the extruded lining may also occur. Therefore, the service life of a lining is limited and depends largely on the specific conditions encountered during its use.
4. The lining of the medium-frequency induction heating furnace should be heated to no more than 2 mm. Cracks no longer than 2 mm must be promptly filled with a suitable filler. If cracks exceed 2 mm, the lining must be reassembled. Therefore, users must take necessary measures in practice to avoid unnecessary consequences when using medium-frequency heating inductors.
5. During the heating process, a large amount of oxide scale that flakes off the workpiece being heated will accumulate inside the medium-frequency induction coil. If the furnace lining is damaged, cracked, or develops fissures, and if it is not cleaned promptly: first, this can easily lead to ignition, triggering the overcurrent protection of the medium-frequency power supply; second, it can easily cause breakdown of the induction coil, resulting in a turn-to-turn short circuit within the coil. Therefore, the scale buildup inside the medium-frequency induction furnace must be cleaned at least once per shift (8 hours).
6. During the heating process, oxide scale tends to accumulate inside the medium-frequency sensor due to the detachment of heated workpieces. If the furnace lining is damaged or cracked, and this oxide scale is not removed promptly, it can—first—easily cause arcing, triggering the overcurrent protection of the medium-frequency power supply; second—easily lead to breakdown of the induction coil, resulting in a short circuit in the induction coil. Therefore, the cleaning interval for oxide scale inside the medium-frequency induction furnace should be at least every 8-hour shift.
7. The newly produced medium-frequency heating inductor, just put into operation, must be baked at low power (typically around 30 kW) and left inside the induction furnace for about 2 hours. The reason is that during the commissioning process, the inductor needs to be filled with water; after commissioning, residual water remains in the sensor tube inside the inductor. Especially in winter, this residual water may even freeze into a very thin layer of ice. Therefore, it is absolutely crucial to follow this procedure. To ensure the longevity of the lining, the new medium-frequency heater must be started up at low power and then begin production only after 2 hours have elapsed.
8. The water-cooled internal guide rail of the medium-frequency heating sensor is, in effect, a motion guide rail that continuously operates under high temperatures to support the heated workpiece. If there isn't sufficient water or water pressure, vaporization, red-hot conditions, and deformation may occur, preventing the heated workpiece from passing through the sensor. Therefore, the cooling function of the water-cooled conduit is also extremely important.
9. The water-cooled guide rails suffer severe wear during operation. Typically, the wall thickness of water-cooled guide rails is 2 mm. Therefore, water-cooled guide rails have a limited service life. If wear becomes excessive, they must be replaced. Otherwise, once a leak occurs, it could cause rapid cooling, directly affecting the performance and lifespan of the furnace lining.
10. Once the dry guide rails (water-sealed) become worn or deformed, they must be replaced immediately. It is strictly prohibited to use the furnace lining as a guide rail for heating workpieces. In short, during operation, it is also essential to regularly inspect and replace the heat-exchange inductor. If any issues are detected, they should be addressed promptly. Only in this way can the inductor function properly without disrupting production.
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Kangda Electric Furnace specializes in the manufacture of the following equipment: KGCL series medium-frequency power supplies, KGPS series medium-frequency power supplies, GTR series medium-frequency induction heating furnaces...
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Address: Yuhe Industrial Park, Weicheng District, Weifang City, Shandong Province
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