At present, foundry enterprises give priority to medium frequency induction furnaces due to environmental protection, charging, human resource costs and other reasons. Its development trend is intelligence, high reliability, high quality, high-quality service, energy conservation and environmental protection. Especially in multi brand production foundry enterprises, the advantages are more prominent.
In the current situation, the following are the requirements of enterprises, which should also be considered when selecting models.
(1) Increase the specific power and control the power consumption at 600kW/t.
(2) The furnace body, power supply system, cooling system and tilting furnace system are of high quality, good reliability and durability, and high degree of automation. They can display, alarm, diagnose and handle faults for each system.
(3) The supplier has strong service ability, high quality and fast response.
(4) There should be detailed technical data and guidance in the use and maintenance, and a long-term cooperative relationship should be established. The price of non-standard parts should be reasonable.
(5) Products with high comprehensive quality can avoid many troubles in the process of use.
Application enterprises need to pay attention to the following outstanding issues during the use of induction furnaces.
First, the reliability of protective circuits for key components such as thyristors and the alarm technology of inductors need to be further improved. There are many non-standard components with expensive prices, incomplete technical data and serious technical fortification. When the power supply system, especially the integrated circuit, fails, it is difficult for users to troubleshoot, and suppliers also respond slowly for some reasons.
Second, the scaling problem of the water cooling system is prominent. The enterprise lacks water treatment technology and guidance, and does not pay enough attention to water quality treatment. It is very difficult to deal with the water temperature alarm caused by scaling. I hope the manufacturer can provide technical support and guidance.
Third, in winter in the north, the cooling tower often freezes and cracks the water pipe, and the sediment makes the water quality worse.
Fourth, the assembled products, many of which are not produced by themselves, lack technical integrity and increase the intermediate links of services. Such products are unreliable.
At present, furnace lining materials are developing rapidly, but enterprises lack technical guidance in the use process, mainly in the following aspects.
First, due to factors such as heat resistance temperature, thermal conductivity and thermal expansion coefficient, quartz sand and magnesia will have some defects that affect smelting quality and lining service life in the process of making, sintering and using furnace lining, and even have safety accidents, such as furnace leakage. It is suggested that the suppliers of electric furnace and refractory materials provide enterprises with more comprehensive furnace lining making, sintering and use technologies, and provide technical guidance and training for different furnace types, smelting alloy types, climates and other factors in the early use of enterprises.
Secondly, the tap hole of induction furnace is always easy to be damaged. When special lining repair materials are used, they feel very hard and cannot be bonded to the furnace lining. It is unclear to what extent the damaged parts are cleaned. It is recommended that the supplier provide technical guidance and detailed instructions, and further study the vulnerability at the furnace mouth.
Thirdly, the sintering of furnace lining is a key link that affects the service life of furnace lining. Enterprises have learned from experience or from brother manufacturers in this link, such factors as heating rate, heat uniformity, how to add cold materials in the crucible, temperature measuring point location, high temperature sintering temperature, and holding time. Its operation and technology need to be strengthened.
At present, there are many manufacturers of furnace lining materials, and the key is to improve the service life of furnace lining, hoping to win by quality.
In addition, after-sales service should not be limited to the warranty period, and long-term, mutually beneficial and win-win cooperation should be established. The manufacturer can set up a regional service center. If the user’s equipment fails or needs technical service guidance beyond the warranty period, the manufacturer can cooperate in the form of contract, respond quickly and provide considerate service. Through the manufacturer’s technical service or technical transformation, the service life of the user’s equipment increases. In the process of technical transformation or upgrading, long-term cooperation can also be established, which is also a good income generating point for the manufacturer. For the user, it eliminates the trouble of maintenance difficulties and lack of technical guidance, reduces maintenance costs, and avoids downtime losses.