西安高盛冶金设备有限公司30公斤真空感应熔炼精密铸造.pdf

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1、ZG-0.03L 周期式真空感应熔炼精密铸造炉技术方案ZG-0.03L 周期式真空感应熔炼精密铸造炉技术方案ZG-0.03L Vacuum Induction Melting Furnace Program forPrecision Casting一、设备用途一、设备用途ZG-0.03L 周期式真空感应电炉是熔炼坩埚封闭在真空室中，利用电磁感应产生的涡流热做热源（电能转换成热能）。在真空状态下进行金属的冶炼并浇铸，从而得到高质量材料的熔炼设备。ZG-0.03Lvacuum induction melting furnace for nickel-based alloys in a vacuum

2、 orambient atmosphere using the principle of induction heating for melting,vacuum casting.主要由炉体、炉盖、合金加料、测温装置、捣料装置、中频电源、进电装置、倾炉浇铸装置、模壳加热炉、真空系统、中频电源、调压加热炉电源、电气控制系统、设备冷却系统等构成Complete set of electric furnace is composed of many components.A furnace body,afurnace cover,alloy feeding,temperature measuring

3、 device,ramming material device,medium frequency power supply,electric supply device,a tilting furnace shell mouldcasting device,heating furnace,vacuum system,medium frequency power supply,adjustable power supply,heating furnace electrical control system,equipment coolingsystem and so on.型号：ZG0.03L

4、表示：30kg 真空感应熔炼炉，立式结构，可控硅中频电源。Modeldescription:ZmeanvacuumGmeaninduction,0.03 mean30KgLmeanvertical structure二、主要参数1、熔炼炉部分二、主要参数1、熔炼炉部分名称单位数值名称单位数值设备总功率千瓦（Kw）130电源电压伏（V）380（三相）电源频率赫（Hz）50额定容量公斤（Kg）30中频电源功率千瓦（Kw）100熔化时间分钟（Min）额定电压（中频输出）伏（V）250-375额定频率赫兹（Hz）2500最高工作温度度（）1750工作温度度（）1700极限真空度帕（Pa）5 X10-3

5、(空炉、冷态、未通水)工作真空度帕（Pa）5X10-2泄漏率帕/小时（Pa/h）4.0抽真空时间：由大气压力下至工作真空度时间20 分钟|（空炉）测温方式热电偶测温（选择配置红外线测温仪）坩埚材质镁砂坩埚冷却水循环量：立方米/小时（m3/h）15.0The main technical indicators:Rated capacity30KgThe total power130KWIF Power100KWIF output frequency:2500HzThe max temperature of1750 Work temperature:1700 Temperature measure

6、ment methodstermocouple and Infrared thermometerMelting time40min minutesCrucible materialsMagnesiaUltimate vacuum5.0 x10-3PascalWork vacuum:5.0 x10-2PascalLeakage rateless than 4 Pascal per hourInert gas:nitrogen or argon or heliumMains supply voltage380VInput Phase:3 phaseInput Power Frequency:50H

7、zInput IF voltage:250-375VCooling water circulation15t/hInput water temperatureless than 55 degreeOut water temperature5 degree to35 degreeWater pressure0.2-0.3MPa;The layout sizeLength:4500mm,Width:3000mm,Height:4000mm2、模壳加热炉：、模壳加热炉：加热方式：电阻加热发热材料：钼带加热温度：1100加热炉电源：调压电源输入电压：36V电源功率：40KW加热炉测温方式：热电偶测温M

8、ould heating furnace parametersMould shell temperature:1200Heating method:Resistance heating furnaceThe heating material:Nickel chrome heating wireThe heating temperature:1200:The power of the heating furnace:Pressure regulatorInput voltage:36VPower:40KWHeating furnace temperature measurement mode:t

9、hermocouple三、工作原理三、工作原理真空感应炉冶炼的优点：真空感应炉冶炼的优点：没有空气和炉渣污染，冶炼的合金纯净，性能水平高；真空下冶炼，创造了良好的去气条件，熔炼出的钢和合金气体含量低；真空条件下，金属不易氧化；原料带入的杂质在真空状态下可以挥发一部分，使材料得到提纯；真空感应炉冶炼时，可以用碳脱氧，脱氧产物是气体，合金纯度高；能准确的调整和控制化学成分；可以使用返回料。The advantages of vacuum induction furnace smelting:1No slag and air pollution，Smelting alloy material mee

10、t the hight purity requirements,，And achieve high performance levels；Under the vacuum smelting,created a good removal of impurity gas conditions，The steeland alloy smelting meet low gas content；Under the condition of vacuum,the metal difficult to oxide；when Raw materials bring impurities,in the vacu

11、um condition can be volatile some ofimpurities，Make the material be purified;When the vacuum induction furnace smelting，You can use carbon deoxidization,deoxidizing products are gases，Alloy of high purity；Accurate adjustment and control of chemical composition；Can use the returned materials。四.ZG-0.0

12、3L 周期式真空感应熔炼炉的结构四.ZG-0.03L 周期式真空感应熔炼炉的结构ZG-0.03L 周期式真空感应熔炼炉主要由：真空熔炼炉体、感应线圈、真空系统、中频电源、电控装置、测温等辅助功能系统、水冷却系统等组成组成。4.ZG-0.025L semi-continuous vacuum induction melting furnace structureZG-0.03L vacuum induction melting furnace is mainly composed of:vacuum meltingfurnace,induction coil,vacuum systems,fre

13、quency power supply,busbars,electric controldevice,temperature and other auxiliary functions of the system,water cooling systemcomponents.4.1熔炼炉体：熔炼炉体：熔炼炉体由主炉体、炉盖、炉盖升降移动机构等组成。熔炼炉体由主炉盖、炉体、侧开门、炉盖升降移动机构等组成。4.1 smelting furnaceSmelting furnace from the main lid,furnace,side door,lid lifting movement mec

14、hanism andother components.4.1.1 炉体 The furnace body4.1.1 炉体 The furnace body熔炼炉体内壁为304不锈钢，外壁及加强筋为Q235碳钢，内外炉壁之间通冷却水的双层立式水冷结构，炉体内外壁之间有加强筋，足够刚度和强度，抽负压不会变形，安全可靠。炉壳制造所用材料经过探伤无裂纹、焊接性能好、受热不易变形、渗气率低，在炉体上设置主真空管道接口、进电接口、进水接口，充、放气阀等接口。炉体上设计有炉门，炉门是模壳出入熔炼炉的通道。也模壳加热炉的一部分。4.2.1 melting chamber furnaceFurnace body

15、 304 stainless steel,cylindrical structure;diameter is 1400mm,height is1600mm,wall and ribs for the Q235 steel,through cooling water between the inner and outerdouble vertical water-cooled furnace wall structure,furnace there stiffener between the bodywall,sufficient stiffness and strength,safe and

16、reliable.Materials used in manufacturingfurnace shell after testing no cracks,good weldability,heat distortion,low gas permeability.In order to facilitate the furnace chamber maintenance equipment and induction coil,meltingfurnace side of the room there is the door,opened the door flange opening,mou

17、nted into thespindle,electric induction coil mounted on the spindle into the inside of the chamber door,furnace outside of the door to install tilting hydraulic cylinders,into electric spindle ishollow coaxial,between water,and an induction coil to form a circular loop.Shaft and into the electric in

18、duction coil mounted on the furnace,using bus andcollector means relatively water-cooled cables have low pressure drop and high reliability.Another side of the furnace holding furnace thermocouple interface is reserved for three,inflatable valve interface.The furnace body is provided with a furnace

19、door,a furnace door is shuttering entrysmelting furnace channel.Also part of the shell mould heating furnace4.1.2 炉盖：4.1.2 炉盖：Furnace cover炉盖采内壁及法兰材质为 304 不锈钢，外壁为碳钢中间通冷却水的双层水冷蝶形封头结构形式；炉盖上设置有：加料、测温、观察视窗等装置、放气阀、压力表等。The furnace cover wall and the flange is made of stainless steel,carbon steel,the oute

20、r wallof the furnace cover is,on top of furnacehave afeeding system,a temperature measuringdevice(temperature infrared temperature measurement and thermal uniformity),observationwindow,vacuum table,Stir bar etc.4.1.3炉盖升降移动机构4.1.3炉盖升降移动机构 Furnacecoverlifting movement mechanism炉盖升降机构，升降机构由升降转轴，连接轴座，轴承

21、、电机、涡轮蜗杆减速机等组成。当要打开炉盖时，首先松开炉盖和炉体之间的拉扣，丝杠将炉盖顶起到一定高度，然后手动将炉盖沿升降轴旋转到炉体偏旁。要封闭炉盖时，手动将炉盖转至炉体的正上方，然后丝杠下落，炉盖也落下，再用拉口将炉盖和炉体卡紧。The furnace cover lifting mechanism,the lifting mechanism is composed of a lifting shaft,connectingshaft seat,bearing,motor,turbine worm reducer etc.When you want to open the furnace

22、cover,releasethe furnace cover and a furnace body pulled between the furnace cover,screw top up to a certain height,and then manually furnace cover lifting furnace body along the axis to the radical.To close the furnacecover,the manual will be just above the furnace cover to the furnace body,and the

23、n screw thewhereabouts,a furnace cover also falls,then pull the mouth the lid and furnace body clamping.4.1.44.1.4观察视镜观察视镜炉盖上装有二个视察孔，双层石英隔热玻璃，能观察到炉内的各个有效位置，同时可供二个人观察炉内熔炼状况、浇注状况、测温、捣料等工作及炉内其他状况等。观察视窗设计独特，每个圆形的观察视窗上安装有 6 块石英玻璃。呈 60 度，6 块观察玻璃可以转动，当一块玻璃脏了，可以旋转用下一块玻璃观察，比只有一块观察玻璃的视窗先进。当 6 块玻璃脏了，可以更换干净的玻璃。

24、The furnace cover is provided with two inspection window,double quartz insulation glass,can observe various effective position within the furnace,at the same time for two personalobservationfurnacesmeltingcondition,temperaturecondition,casting,rammingotherconditions such as work material and furnace

25、 etc.The observation window design is unique,each round of the observation window is providedwith 6 pieces of quartz glass.A 60 degree,6 pieces of glass observation can rotate,when a pieceof glass is dirty,can rotate with a piece of the glass observation,than only a piece of glasswindows advanced ob

26、servation.Glass dirty can replace the clean glass.合金加料器合金加料器Alloy feederAlloy feeder为了在真空熔炼过程中添加各种元素，因此在炉盖上装有特制的五-六格加料器，它有盖，能把加料器进行真空密封。在熔炼抽真空之前，把元素预先放在加料器中，在添加元素时借手轮转动加料器对准分度，元素便从开口落到料斗上，另有一手把柄翻转料斗，把元素送到坩埚上口后，有一块控料板，就自动打开，让斗内的元素从靠近熔融金属液面上流入，避免喷溅，然后借弹簧扭力自动复位。Alloy feeder,adding alloy elements to the

27、 crucible in melting,modification of thecomposition of molten steel.测温测温Temperature measuring配置红外线测温和热电偶测温两种测温装置。红外线实时在线测温，热电偶进行校正。红外线测温配置美国雷泰 MR1S 型双比色红外线测温仪。测温范围 1000-1800.双比色红外线测温仪见下图。双色红外线测温仪垂直于熔炼坩埚内钢液，为了防止金属挥发气体干扰测量结果，测温时向炉内充入氩气。The temperature measuring device:Configuring two kinds of infrared

28、 temperature measurement and thermocouple temperaturemeasurement devices.Infrared real-time online temperature,thermocouple calibration.US Raytek infrared temperature measurement configuration MR1S double colorimetricinfrared thermometer.Temperature range of 1000-1800.Double colorimetric infraredthe

29、rmometer shown below:热电偶测温为即时测温，热电偶插入钢液中测温，防止红外线测温时由于金属蒸汽挥发污染测温玻璃，测量数据不准确，另外热电偶测温也可以对红外线测温仪进行校正。热电偶测温使用超高温钨铼热电偶，测温范围为 02000，其结构为单层保护管，保护管选用10 厚壁钼镁管,热偶丝采用0.5mm WRe5/26，D 分度热偶丝。热电偶测温装置为电动升降操作。Thermocouple for immediate temperature measurement,infrared thermometer can becorrected.Thermocouple using ult

30、ra-high temperature tungsten-rhenium thermocouples,temperature range of 0 1600,its structure as a single protection tube,protection tube10 thick molybdenum selection magnesium tubes,thermocouple wire using 0.5mmWRe5/26,D indexing thermocouple wire.Thermocouple temperature measuring device forelectri

31、c operation.4.2 感应熔炼系统 Induction melting system4.2 感应熔炼系统 Induction melting system由水冷进电铜轴、感应器、倾炉机构、绝缘密封装置等组成。Including the induction coil,water cooled copper shaft,into the electric furnacetilting mechanism,the insulation sealing device etc.水冷导电铜轴 The conductive shaft水冷导电铜轴 The conductive shaft水冷导电铜

32、轴是熔炼炉的重要部件，安装在炉体上，炉内部安装感应线圈，炉外部分与中频电源导电铜排连接，其作用是将由中频电源输送来的低压大电流输送给感应线圈，因此水冷导电铜轴具有导电、绝缘、密封和冷却的功能。本设备的水冷导电铜轴采用空心厚壁紫铜管作导电用。空心铜管内通以冷却水起冷却作用。水冷导电铜轴通过炉体上的旋转法兰与炉体连接，旋转法兰与炉体之间采用动态密封作用，既可以旋转动作也起到密封作用。电极为双层铜管，两层铜管之间有一定的间隔，冷却水从内层铜管的进入，流经感应线圈后，回水从两层铜管之间的间隙流出，电极和线圈形成一个循环水路。同时，导电铜轴也是倾炉机构的主要组成部分。The water cooling

33、conductive copper axles are main part of the melting furnace,which is equipped in the furnace body.Inside is the induction coil and outside connected with the copper platoon of the power supply.It transport the low voltage,high current from the medium frequency power supply to the induction coil.Thu

34、s,the copper axles have the function of electricity conduction,insulation,sealing and cooling.The water cooling conductive copper axles adopts hollow thick wall copper pipe as electricity conductor,where the cooling water flows through.The rotatable flanges in the furnace body connect the water cool

35、ing conductor copper axles and the furnace body.The dynamic packing between the rotate flanges and furnace body promotes both the rotation and sealing.At the same time,the conductive copper axles are also main parts of the tilt furnace structure.4.2.1 感应线圈：感应线圈：Coil感应线圈用扁圆形 T2 空心紫铜管绕制成，内径 330,，高度 38

36、0mm,共 6 匝，匝与匝之间有10 毫米的间隙，感应线圈两边用绝缘胶木板固定，线圈刷绝缘油漆，并进行烘烤，进行绝缘处理。，感应线圈和进电铜轴的连接是用两个铜法兰连接，拆卸方便。密封圈密封，保证不会漏水漏气。在线圈的底部朝内焊有四块不锈钢支撑板，用来支托坩埚。在四块不锈钢支撑板放置一块厚度20mm 的石棉板，坩埚放入线圈内，线圈和坩埚之间的缝隙用镁砂打结材料填充结实，烘烤，The coil is made of copper winding,the diameter is 330,mm,the heightis 380mm,6 turnThere is a gap of 10 mm betwe

37、en turns and turns，Both sides of the coil are used insulating rubber boardfixed，Coil insulating paint brush，Baking,insulation treatment，Connect the coil and the electrode isconnected with the two copper flange.At the bottom of the coil are welded in four pieces of stainless steel support plate for s

38、upporting thecrucible.In the four block of stainless steel support asbestos board placed a thickness of 20mm,thecrucible into the coil,the gap between the coil and the crucible for magnesia knotting materials filledgrain,baking电极上面有 2 套水冷铜套，每个铜套内镶有 1 个石墨环，石墨环套装在电极上，石墨环和电极接触，起到导电和摩擦旋转的作用。The electrod

39、e above has 2 sets of water cooling copper sleeve,each of the copper sleeve isinlaid with 1 graphite rings,graphite ring is sheathed on the electrode,and the electrode contactto graphite ring，conductive and friction rotating effect.4.2.2 倾炉机构：倾炉机构：感应线圈倾翻为手控液压倾动，能够前倾100、后倾10，炉外控制，翻转速度可调节。炉嘴可最大限度地减少浇注

40、时候钢液流的水平位移，易于把钢水浇铸入模壳。Coil tipping for manual control hydraulic tilting,forward to 100 degrees，backward to 10degrees,turning speed adjustable.Furnace mouth can minimize horizontal displacement pouringsteel liquid flow,easy to molten steel casting into the mold shell。液压系统液压系统 Hydraulic system液压系统为炉盖升

41、降和线圈倾转提供动力，液压系统由高压泵站、管道及开关、液压活塞缸等部件组成。Hydraulic system for furnace coverlifting and coil tilt hydraulic systemprovides power,high-pressure pump,pipeline and switch,hydraulic pistoncylinder and other components.4.3、锭模加热电炉：、锭模加热电炉：加热炉技术参数加热炉技术参数加热方式：电阻加热发热材料：钼带或石墨加热温度：1100加热炉电源：可控硅调压电源电源功率：40KW加热炉尺寸：直

42、径 400mm高度 500mm图为模壳加热炉和电源调压变压器Mould heating furnace parametersMould shell temperature:1200Heating method:Resistance heating furnaceThe heating material:Nickel chrome heating wireThe heating temperature:1200:The power of the heating furnace:Pressure regulatorInput voltage:36VPower:40KWHeating furnace

43、 temperature measurement mode:thermocoupleMould heating furnace锭模加热炉是用来对模壳进行加热的电炉，为电阻加热炉，用钼带发热体，最高工作温度 1200度，为了保证型壳的浇铸时要求的温度，加热炉结构从内到外依次：发热体-陶瓷纤维保温材料-氧化铝保温层-不锈钢炉壳，加热炉的上方开设直径 100mm 圆孔，架设漏斗用于浇铸。电阻加热为两部分，一部分固定在炉室内感应线圈下前方，一部分固定在炉门上，随炉门开关。模壳加热炉通过水冷电极将由变压器输送来的低压大电流输送给加热器，因此水冷电极具有导电、绝缘、密封和冷却的功能。本设备的水冷电极采用空

44、心厚壁紫铜管作导电用。空心铜管内通以冷却水起冷却作用。炉体和炉门上分别有 3 个水冷电极。是将由变压器输送来的低压大电流输送给加热炉，因此水冷电极具有导电、绝缘、密封和冷却的功能。本设备的水冷电极采用空心厚壁紫铜管作导电用。空心铜管内通以冷却水起冷却作用。水冷电极通过炉体上的 3 个法兰与炉体连接，同时起密封作用根据工艺可以在加热炉上方有挡渣板，防止熔炼过程中飞溅的钢水掉入模具内。挡渣板为不锈钢材质，炉外手柄操作开启和闭合。根据工艺可以在加热炉上方有挡渣板，防止熔炼过程中飞溅的钢水掉入模具内。挡渣板为不锈钢材质，炉外手柄操作开启和闭合。为了保证加热对模壳加热的均温性，1 个测温点，测温采用钨铼

45、热电偶测温仪。来控制加热炉炉温加热炉电源为可控硅电源，调整加热炉的温度，升温、降温、恒温。加热炉电源为可控硅电源，调整加热炉的温度，升温、降温、恒温。Ingot mold furnace is used to heat the mold furnace,induction furnace resistance,graphiteheating element,the maximum operating temperature of 1800 degrees,in order to ensure thecasting shell when the desired temperature,the f

46、urnace structure from inside to outside:graphite heating element-carbon graphite felt insulation layer-high temperature fiber feltinsulation layer-the induction coil,the outermost layer of heat-resistant steel for 2520.Playa strong role in the insulation.100mm diameter above the furnace opening hole

47、,for casting.According to the process at the top of the furnace may have slag board,to prevent splashingof molten steel smelting process fall into the mold.Slag board for the outer stainless steeloven handle opening and closing operations.3 water cooled electrode are respectively arranged on the fur

48、nace body and afurnace door.Electrode current power brought transport to the heating furnace,Water cooled electrode with conductive,insulation,sealing and cooling function.The use of hollow copper conducting electrode with.In the copper pipe is filled with cooling water from the cooling effect.Water

49、 cooled electrode connected through 3 flange and the furnace body of the furnace bodyalso has the function of sealingSet an oven temperature measurement points,temperature thermocouple thermometer.SCR frequency power supply for the furnace to adjust the temperature of the furnace,heating,cooling,the

50、rmostat.真空感应熔炼炉坩埚要求：真空感应熔炼炉坩埚要求：Vacuum induction furnace melting in crucible requirements:1、坩埚有高的热稳定性，避免坩埚急冷急热产生裂纹；1,the crucible has high thermal stability,avoid the crucible sudden cold and hot crack;2、坩埚化学稳定性，防止耐火材料对坩锅污染；2,the crucible chemical stability,prevent pollution of crucible refractory m