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China Suppliers Electromagnetic Heating Machine for Hot Heading Thick Iron Bars in Factory
Product Description
Compared to traditional resistance furnaces, it offers significant energy-saving benefits, achieving up to 30%-50% reduction. The precise temperature control system (±10°C) effectively prevents oxidation and decarburization, enhances the density and grain refinement of forgings, and reduces mold thermal stress, extending the service life of molds by 40%. Additionally, the equipment features a PLC intelligent control system, with support for parameter memory, fault diagnosis, and industrial Internet of Things interfaces, fulfilling the automation requirements of modern forging production lines, and is particularly well-suited for the mass production of high-precision irregular parts.
Application Scope
Widely applied in the through-heating and temperature compensation of materials such as bar stock, round steel, square steel, and steel plates, as well as online heating and local heating. It plays a significant role in the online forging of metal materials (e.g., gears, semi-axle connecting rods, bearings, and other precision forging), extrusion, hot rolling, heating before shearing, heating for spraying, and hot assembly processes. Additionally, it is used in the heat treatment processes of metal materials, including overall tempering, annealing, and tempering.
Configuration and Performance
This electromagnetic induction heating equipment features a high-frequency inverter power supply (380V/50Hz, customizable for 440V/60Hz) and a water-cooled copper heating coil specifically designed for iron bars with diameters of 20-80mm. The control system integrates PLC temperature control module, supported by a dual-channel closed-loop water-cooling system (3m³/h flow rate), ensuring stable operation with overload protection and emergency stop functionality.
Rapid Heating: Heats Ø60mm iron bars to 1200°C within 90 seconds.
High Efficiency: Over 85% electrothermal conversion efficiency.
Low Material Loss: Oxidation loss reduced to 0.3%.
Continuous Operation: Supports 24/7 run with 15-min cooldowns.
Key performance includes a 120kW maximum power output and 1–20kHz frequency adjustment range, achieving temperature control accuracy of ±1% of the setpoint. The compact unit measures 1200×800×1600mm, facilitating workshop integration. Actual performance may vary slightly based on material properties and environmental conditions.
Ideal for precision hot-heading processes like automotive fasteners and aerospace forgings, the system optimizes metal plasticity through rapid, uniform heating. Its enclosed water-cooled design and automated temperature control significantly reduce energy consumption, complying with ISO 9001 standards, with a 1-year warranty included.
Note: Performance parameters are based on standard operating tests. Users are advised to conduct process validation according to specific production requirements.
Technical Specifications
1. Power & Electrical
- Input Power: 380V/50Hz (440V/60Hz opt.)
- Max Output: 120 kW
- Frequency Range: 1–20 kHz adjustable
- Electrothermal Eff.: ≥85%
2. Thermal Performance
- Heating Speed: 0→1200°C in ≤90s (Ø60mm)
- Temp Uniformity: ±5°C
- Control Accuracy: ±1% of setpoint
- Oxidation Loss: ≤0.3%
3. Cooling System
- Type: Dual-channel closed-loop
- Flow Rate: 3 m³/h
- Duty Cycle: 24/7 (≤15min cooldown)
4. Mechanical & Control
- Heating Coil: Copper (Ø20–80mm bars)
- Control System: Touch HMI + PLC PID
- Dimensions: Customized
5. Safety & Compliance
- Protections: Overheat, overcurrent, e-stop
- Warranty: 1 year
Application Scenarios
Frequently Asked Questions
Q
How much energy can this induction heating equipment save compared to traditional furnaces?
Compared to traditional resistance furnaces, this electromagnetic induction heating equipment offers significant energy-saving benefits, achieving up to a 30% to 50% reduction in energy consumption.
Q
What is the heating speed and temperature control accuracy of the system?
The system can heat a Ø60mm iron bar to 1200°C within 90 seconds. It features a precise temperature control system with a temperature uniformity of ±5°C across the workpiece and a control accuracy of ±1% of the setpoint.
Q
What range of workpiece sizes does the heating coil accommodate?
The water-cooled copper heating coil is specifically optimized for heating iron bars with diameters ranging from 20mm to 80mm.
Q
Does the equipment support continuous operation?
Yes, the equipment is designed for 24/7 continuous operation, requiring only brief cooling intervals of 15 minutes or less, supported by a dual-channel closed-loop water-cooling system.
Q
What safety protections are integrated into the equipment?
The system integrates comprehensive safety safeguards, including protection against overheat, overcurrent, short circuits, phase failure, and a built-in emergency stop functionality.
Q
What are the main applications of this induction heating equipment?
It is widely used for through-heating, online forging, extrusion, hot rolling, tempering, annealing, and local heating of metal materials such as bar stock, round steel, square steel, and steel plates.