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一、鋼坯加熱爐,鋼坯感應(yīng)加熱爐,鋼坯加熱設(shè)備概述
PLC自控系統(tǒng)，國內(nèi)組裝,世界一流技術(shù)、本地化服務(wù)、最低價(jià)格
1、進(jìn)出料機(jī)構(gòu)、線圈和電源一體化設(shè)計(jì)，所需基建、工場占地和安裝時間都較少。
2、并聯(lián)式中頻電源設(shè)計(jì)，AC電壓靠二極管轉(zhuǎn)化為DC電壓，能量轉(zhuǎn)換效率96％。
3、 輸出功率可在10％－100％之間調(diào)節(jié)，所有功率范圍都能維持0.96功率因素，諧波畸變污染少。
4、由于電源傳輸距離短、采用特殊隔熱材料、串連式電源逆變測電流小電壓高，中頻單耗很低。
5、動態(tài)監(jiān)測串連諧振線圈負(fù)載電流變化情況，及時閉環(huán)控制電源輸出功率，保證加熱溫度穩(wěn)定
6、 其它豐富的檢測、自診斷、報(bào)警功能和安全防護(hù)裝置。
7、 關(guān)鍵元器件進(jìn)口，采用高品質(zhì)電氣部件，國內(nèi)組裝；世界一流技術(shù)、本地化服務(wù)和價(jià)格。
8、根據(jù)坯料大小選配不同的加熱頻率，節(jié)省耗電量；線圈適應(yīng)坯料直徑范圍寬1倍。
9、內(nèi)嵌式的操作盤顯示機(jī)器運(yùn)行狀態(tài)并供故障診斷之用；可以選擇手動或人機(jī)界面操作方式。
10、 標(biāo)配電源內(nèi)置閉式內(nèi)循環(huán)蒸餾水冷卻系統(tǒng)，可以選配線圈內(nèi)水系統(tǒng)或提供整套水冷解決方案。
11、可以選擇氣動或變頻夾輥輪進(jìn)料機(jī)構(gòu)；快速抽取出料系統(tǒng)帶破除粘結(jié)機(jī)構(gòu)并可選配溫度分揀系統(tǒng)。
二、鋼坯參數(shù)及工藝要求
u 鋼坯尺寸130x130 mm ，12 m、
u 鋼坯頭部溫度: 表面 940 °C – 芯部 1030 °C – 平均 960 °C
u 鋼坯尾部溫度: 表面 925 °C – 芯部 985 °C – 平均 938 °C
u 從頭到尾經(jīng)過時間: 109 s –速度 0.11 m/s – 產(chǎn)量51.5 t/h
u 150x150 mm 12 m
u 鋼坯頭部溫度: 表面949 °C –芯部1065 °C – 平均 975 °C
u 鋼坯尾部溫度: 表面933 °C – 芯部 1005 °C – 平均 948 °C
u 從頭到尾經(jīng)過時間: 145 s – 速度0.083 m/s – 產(chǎn)量51.8 t/h
u 要求第一架軋機(jī)入口頭尾均等溫度，最低 1050 °C現(xiàn)場工作條件：
三、 電源頻率與功率的平面布置的確定:
u 根據(jù)坯料最大尺寸150x150 mm 12 m 經(jīng)計(jì)算頻率范圍在1600Hz～600Hz范圍內(nèi),本加熱爐頻率確定為1000Hz。
u 根據(jù)最大坯料150x150 mm 12 m 重量（2080公斤）和生產(chǎn)率(145秒/每件)計(jì)算所需加熱功率最大為1500kw，此功率可以滿足所有的鋼坯加熱及保溫。
四、 設(shè)備范圍與功能描述:
1.設(shè)備范圍見下表
|
序號 |
內(nèi)容 |
數(shù)量 |
備注 |
||
|
1 |
12脈整流變壓器1500KVA |
1臺 |
|
||
|
2 |
連接銅排 |
|
|
||
|
2 |
晶閘管中頻電源KGPS-1500/1 |
2套 |
|
||
|
|
|
|
|
||
|
3 |
感應(yīng)加熱器 |
1套 |
|
||
|
3.1 |
GTR130(鋼坯尺寸130x130mm12m) |
1套 |
|
||
|
|
GTR150(鋼坯尺寸150x150mm12m) |
|
|
||
|
4 |
感應(yīng)加熱器床身 |
1套 |
|
||
|
5 |
進(jìn)料裝置 |
1套 |
|
||
|
6 |
出料裝置 |
1套 |
|
||
|
7 |
動力控制柜 |
1套 |
|
||
|
8 |
溫控系統(tǒng)(紅外線測溫和控制儀) |
1套 |
|
||
|
8.1 |
PLC中央控制臺 |
1套 |
|||
|
8.2 |
可編程控制器 |
1套 |
|||
|
8.3 |
液晶屏 |
1套 |
|||
|
8.4 |
雙比色紅外測溫儀 （西安瑞光） |
1臺 |
|||
|
8.5 |
光電報(bào)警開關(guān) |
1套 |
|||
|
8.6 |
控制柜 |
1臺 |
|||
|
A、綜合參數(shù) |
||
|
序號 |
項(xiàng)目 |
參數(shù)要求 |
|
1 |
電源功率 |
1500kw / 3相6脈 |
|
2 |
整流項(xiàng)數(shù) |
12脈 |
|
3 |
逆變器 |
SCR并聯(lián)逆變 |
|
4 |
額定頻率 |
1000Hz以上 |
|
5 |
進(jìn)線電壓 |
660V |
|
6 |
中頻電壓 |
1600V |
|
7 |
啟動成功率 |
100% |
|
8 |
功率因數(shù) |
大于0.92 |
|
9 |
出口加熱溫度 |
1150℃ |
|
10 |
加熱溫升電耗 |
≤60±5% kW.h/t |
|
11 |
加熱時間 |
145秒/根 |
|
|
|
|
|
B、熱交換冷卻水系統(tǒng)參數(shù) |
||
|
序號 |
項(xiàng)目 |
參數(shù) |
|
1 |
進(jìn)水壓力 |
0.2-0.4MPa |
|
2 |
進(jìn)水溫度 |
5-35℃ |
|
3 |
出水溫度 |
<55℃ |
整流變壓器是為中頻電爐提供整流電源的專用變壓器，該變壓器（全紫銅芯油浸式）具有過載能力強(qiáng)，諧波電流少，冷卻效果好等特點(diǎn)。
整流變壓器技術(shù)參數(shù)：
|
型號： |
超負(fù)荷型ZS11-1500KVA/10KV/660v |
|
額定容量： |
Se=1500kva |
|
一次電壓： |
U1=10000V±5% 6相 12脈 50HZ |
|
一次電流： |
I1=86A |
|
二次電壓： |
U2= 660Vx2 |
|
二次電流： |
I2=650x2A |
|
調(diào)壓方式： |
三檔無勵磁手動調(diào)壓 |
|
聯(lián)結(jié)組別： |
D/d。-yn11 |
|
阻抗電壓： |
Z75o=6.5% |
|
效率： |
≥97% |
1500kw 中頻電源主要元器件型號及廠家
|
序號 |
名 稱 |
規(guī) 格 型 號 |
數(shù)量 |
生 產(chǎn) 廠 家 |
||
|
1 |
整流可控硅 |
KP1000A，2000V |
12 |
湖北襄樊臺基 |
||
|
2 |
萬能斷路器 |
DW15-1600A |
2 |
浙江兆宇 |
||
|
3 |
可控硅散熱器 |
SS14-BL |
6 |
溫州愛安特 |
||
|
4 |
吸收電容 |
0.47uF2000V |
12 |
國營794廠 |
||
|
5 |
吸收電阻 |
150W15Ω |
12 |
蘇州恒德電訊 |
||
|
6 |
平波電抗器 |
3mH |
2 |
自制 |
||
|
7 |
進(jìn)線電抗器 |
Φ100*16 |
6 |
自制 |
||
|
8 |
儀表 |
42型 |
6 |
人民電器，上海浦江 |
||
|
9 |
銅材 |
|
|
洛銅 |
||
|
10 |
逆變可控硅 |
KK2000A，2000V |
8 |
湖北襄樊臺基 |
||
|
11 |
可控硅散熱器 |
SS15-BL |
4 |
溫州愛安特 |
||
|
12 |
逆變吸收電容 |
0.47uF2000V |
8 |
國營794廠 |
||
|
13 |
逆變吸收電阻 |
300W15Ω |
8 |
蘇州恒德電訊 |
||
|
14 |
諧振電容器 |
RFM1.2-2000-0.5S |
10 |
浙江建的盛和 |
||
|
15 |
液壓站 |
|
|
山西榆次 |
||
First, billet heating furnace, billet induction heating furnace, billet heating equipment overview
PLC automatic control system, domestic assembly, world-class technology, localized service, lowest price
1. The integrated design of the feeding and discharging mechanism, coil and power supply requires less infrastructure, workshop occupation and installation time.
2. Parallel intermediate frequency power supply design, AC voltage is converted into DC voltage by diode, and energy conversion efficiency is 96%.
3. The output power can be adjusted between 10% and 100%. All power ranges can maintain 0.96 power factor, and harmonic distortion is less polluted.
4, due to the short transmission distance of the power supply, the use of special insulation materials, series-connected power supply inverter measurement current small voltage high, medium frequency single consumption is very low.
5. Dynamically monitor the change of the load current of the series resonant coil, and timely control the output power of the power supply to ensure the heating temperature is stable.
6, other rich detection, self-diagnosis, alarm function and safety protection device.
7, the import of key components, the use of high-quality electrical components, domestic assembly; world-class technology, localization services and prices.
8. According to the size of the blank, different heating frequency is selected to save power consumption; the coil is adapted to the diameter of the billet to be 1 times wider.
9. The embedded operation panel displays the running status of the machine and is used for fault diagnosis; manual or man-machine interface operation mode can be selected.
10, standard power supply built-in closed internal circulation distilled water cooling system, you can choose the inner water system of the coil or provide a complete set of water cooling solutions.
11. The pneumatic or variable frequency nip roller feeding mechanism can be selected; the quick extraction and discharging system can eliminate the bonding mechanism and can be equipped with a temperature sorting system.
Second , billet parameters and process requirements
2.1、Billet size 130x130 mm , 12 m , Billet head temperature: surface 940 °C – core 1030 °C – average 960 °C
2.2、 Billet tail temperature: Surface 925 °C – Core 985 °C – Average 938 °C
2.3、 Elapsed time from start to finish: 109 s – speed 0.11 m/s – output 51.5 t/h
2.4 150x150 mm 12 m
2.5、Billet head temperature: Surface 949 °C – Core 1065 °C – Average 975 °C
2.6、Billet tail temperature: Surface 933 °C – Core 1005 °C – Average 948 °C
2.7、 Elapsed time from start to finish: 145 s – speed 0.083 m/s – output 51.8 t/h
2.8、 The first mill is required to have the same temperature at the head and tail of the first mill, and the minimum working temperature is 1050 °C:
Third, Determination of the plane arrangement of the power frequency and power:
According to the maximum size of the billet 150x150 mm 12 m, the calculated frequency range is in the range of 1600 Hz to 600 Hz, and the frequency of the furnace is determined to be 1000 Hz.
Calculated according to the maximum billet 150x150 mm 12 m weight (2080 kg) and productivity (145 seconds / piece), the required heating power is up to 1500 kw, which can meet all billet heating and insulation.
Fourth, Device range and function description:
1. Equipment range is shown in the table below
|
Serial number |
content |
Quantity |
Remarks |
|
|
1 |
12-pulse rectifier transformer 1500 KVA |
1 set |
|
|
|
2 |
Connecting copper bars |
|
|
|
|
2 |
Thyristor intermediate frequency power supply KGPS-1 5 00/1 |
2 sets |
|
|
|
|
|
|
|
|
|
3 |
Induction heater |
1 set |
|
|
|
3.1 |
GTR130 (slab size 130x130mm12m) |
1 set |
|
|
|
|
GTR150 (slab size 150x150mm12m) |
|
|
|
|
4 |
Induction heater bed |
1 set |
|
|
|
5 |
Feeding device |
1 set |
|
|
|
6 |
Discharge device |
1 set |
|
|
|
7 |
Power control cabinet |
1 set |
|
|
|
8 |
Temperature control system (infrared temperature measurement and control instrument) |
1 set |
|
|
|
8.1 |
PLC center console |
1 set |
||
|
8.2 |
Programmable Controllers |
1 set |
||
|
8.3 |
LCD screen |
1 set |
||
|
8.4 |
Double colorimetric infrared thermometer (Xi'an Ruiguang) |
1 set |
||
|
8.5 |
Photoelectric alarm switch |
1 set |
||
|
8.6 |
Control cabinet |
1 set |
||
|
A, comprehensive parameters |
||
|
Serial number |
project |
Parameter requirement |
|
1 |
Power supply |
1 5 00kw / 3 phase 6 veins |
|
2 |
Number of rectifiers |
12 veins |
|
3 |
Inverter |
SCR parallel inverter |
|
4 |
Rated frequency |
Above 1000Hz |
|
5 |
Line voltage |
660V |
|
6 |
IF voltage |
1600V |
|
7 |
Start success rate |
100% |
|
8 |
Power factor |
Greater than 0.9 2 |
|
9 |
Outlet heating temperature |
1150 ° C |
|
10 |
Heating temperature rise power consumption |
≤ 60 ±5% kW.h/t |
|
11 |
heating time |
145 seconds / root |
|
|
|
|
|
B. Heat exchange cooling water system parameters |
||
|
Serial number |
project |
parameter |
|
1 |
Inlet pressure |
0.2-0.4MPa |
|
2 |
Inlet temperature |
5-35 ° C |
|
3 |
Effluent temperature |
<55°C |
The rectifier transformer is a special transformer that provides rectification power for the intermediate frequency electric furnace. The transformer (full copper core oil immersion type) has the characteristics of strong overload capability, less harmonic current and good cooling effect.
Rectifier transformer technical parameters:
|
model: |
Overload type ZS11- 1500 KVA/10KV /660v |
|
Rated Capacity: |
Se= 1500kva |
|
Primary voltage: |
U1=10000V±5% 6- phase 12-pulse 50HZ |
|
Primary current: |
I1= 86 A |
|
Secondary voltage: |
U2= 660Vx2 |
|
Secondary current: |
I2= 650x2A |
|
Pressure regulation method: |
Three-speed manual non-excitation regulator |
|
Connection group: |
D/d. -yn11 |
|
Impedance voltage: |
Z75o=6.5% |
|
effectiveness: |
≥ 97% |
1500kw intermediate frequency power supply main components and manufacturers
|
Serial number |
name |
Specification model |
Quantity |
Manufacturer |
|
1 |
Rectifier thyristor |
KP 1000 A, 20 00V |
12 |
Hubei Xiangfan Taiji |
|
2 |
Universal circuit breaker |
DW15- 1600 A |
2 |
Zhejiang Zhaoyu |
|
3 |
Thyristor radiator |
SS14-BL |
6 |
Wenzhou Love |
|
4 |
Absorption capacitor |
0.47uF2000V |
12 |
State-owned 794 factory |
|
5 |
Absorption resistor |
150W15Ω |
12 |
Suzhou Hengde Telecommunications |
|
6 |
Flat wave reactor |
3mH |
2 |
self made |
|
7 |
Line reactor |
Φ100*16 |
6 |
self made |
|
8 |
meter |
Type 42 |
6 |
People's Electric, Shanghai Pujiang |
|
9 |
Copper |
|
|
Copper |
|
10 |
Inverter thyristor |
KK 2000 A, 2 0 00V |
8 |
Hubei Xiangfan Taiji |
|
11 |
Thyristor radiator |
SS15-BL |
4 |
Wenzhou Love |
|
12 |
Inverter absorption capacitor |
0.47uF2000V |
8 |
State-owned 794 factory |
|
13 |
Inverter absorption resistor |
300W15Ω |
8 |
Suzhou Hengde Telecommunications |
|
14 |
Resonant capacitor |
RFM 1.2 - 2 000- 0.5 S |
10 |
Shenghe of Zhejiang Construction |
|
15 |
Hydraulic station |
|
|
Shanxi Yuci |
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