GREEN AUTOMATION 2007

Aug 2-3, 2007

LATEST TRENDS IN INDUCTION
MELTING AND AUTOMATIC
POURING SYSTEMS

MELTING & POURING SYSTEMS

HEATING & HARDENING SYSTEMS

TUBE & PIPE WELDING SYSTEMS

Basic Requirements from an Induction Furnace Productivity , Operating Cost , Safety

1. Fastest Melt Rates.

2. Lower energy consumption.
3. Lower kVA requirement.
4. Higher power factor & Lower Harmonic distortion.
5. Safety.

BASIC PRINCIPLE
CURRENT FLOW HEATS THE METAL CHARGE

VOLTAGE-FED INVERTER TECHNOLOGY

TECHNOLOGY
APPLIED
APPLIED BY
BY INDUCTOTHERM
INDUCTOTHERM
THREE PHASES OF AC
ARE CONVERTED TO
SINGLE PHASE DC. DC
ENERGY STORED IN
CAPACITORS

A CONSTANT DC
VOLTAGE IS
APPLIED TO THE
INVERTER

THE FURNACE COIL AND

CAPACITOR BANK ARE
CONNECTED IN SERIES

POWER-TRAKING ACHIEVES
FASTEST MELT RATES
The VIP Power-Trak Systems track the power regardless of changing furnace conditions. Full
power from start to finish for fastest melting.

DUAL-TRAK
A full melting cycle consist of the time for1. Initial Charging
2. Melting
3. Deslagging
4. Chemistry Analysis and Adjustment
5. Pouring

Utilization Factor =

Melting time
Cycle time

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DUAL-TRAK

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DUAL-TRAK

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ADVANTAGES OF A DUAL TRAK

Power utilization of almost 100%.
Batch production capability of two power supplies

in a

single unit.
25 to 30% more metal output for a given kVA.
Uninterrupted metal flow.
Availability of liquid metal from both furnaces if
required.
Power sharing between two furnace in any ratio.

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STEEL SHELL FURNACES STRUCTURAL STRENGTH

Steel

Shells

gives

the

hoop strength
furnace

superior

strength.

Rugged

construction

distortion during

minimizes

tilting

and

pouring.

Low noise level because of sound

deadening

characteristics

of

solid steel shell.

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STEEL SHELL FURNACES HIGHLY

EFFICIENT

Thick walled coils reduce coil losses and put

more energy into the metal.

Open Coil spacing enhances coil efficiency.

Appropriately contoured & larger coverage

of magnetic shunts for re-directing electromagnetic field into the metal

and

to

reduce excessive shell heat-up.

Insulated furnace lids

minimize radiation

losses.

Cooling coils extend lining life.

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STEEL SHELL FURNACES SAFE TO

OPERATE

Shell Protects the coil in the event of

metal splash.
Serves as barrier
between the splashed metal and the
coil.

Higher freeboard protects workers

from excessive heat when the lid is
off.

Open
bottom provides
superior
ventilation reducing moisture build-up
and damage in the event of metal runout.

Fume rings/Fume hoods are provided to

remove smoke and fumes to protect
workers from air pollution.
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SUPERIOR GROUND LEAKAGE

DETECTOR SYSTEM
Probes Must
Be in Contact
With Metal

GLD Probe

Bottom of
Metal Bath

Wire To
Ground

Pusher Block
Bottom Of
Furnace Shell

The Ground Leak Detector system

includes both GLD module associated

with Power Supply and GLD probe located in the furnace.

The system

indicates and shuts off the power when metal penetrates the furnace
lining

into

the

coil

or

when

excessive

moisture

is

present

in

the

furnace or when low ground resistance exists in the electric system. 17

SUPERIOR LINING PUSH-OUT

TECHNOLOGY
Furnace

Coil

Pusher Block
Pusher Block
Extended

Removable Push-Out
Mechanism
Rammed Lining
Hydraulically powered push-out mechanism distributes pressure
uniformly up the side walls of the refractory. The complete
lining can be removed almost entirely in one piece .

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STEEL SHELL FURNACES FUME HOOD

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STEEL SHELL
FURNACES - BACK TILT
SLAGGING

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STEEL SHELL FURNACES LOAD CELLS

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MELT MINDER - FURNACE DETAILS SCREEN

1.

Displays power, weight, and

temperature readings.

2.

Displays temperature set

points (Normal operating
mode).

3.

Displays kilowatt-hour total

(kWatt hour operating
mode).

4.

Displays general furnace

information.

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MELT MINDER - SINTER SCREEN

Sets the sinter recipe for furnace Starts and charts the sintering
process .

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MELT MINDER - STRIP CHART SCREEN

Displays, charts and prints selectable information for all heats over 24hour period for a specific date

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AUTOMATIC POURING SYSTEMS

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AUTOMATIC POURING SYSTEMS

FILLS THE MOULD

PROVIDES STORAGE
REDUCES MANPOWER
REDUCES REJECTS
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PRESSURE POURING FURNACE

1 Vessel
7

2 Inlet

3 Outlet
4 Inductor
5 Pressure
supply
6 Float

7 Stopper
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UNHEATED TUNDISH POURING SYSTEM

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