Aluminum Shell Induction Melting Furnace

Aluminum Frame Induction Furnaces

Aluminum shell induction melting furnace is with the most convenient and economical design among the furnace body.
Cooldo provides induction furnace for ferrous metals (iron & steel) and non-ferrous metal that gives you superior performance & minimizes the heat loss.The Power supply of the aluminum Frame melting furnace Varies from 100kw t0 3000KW.

Features

Usage: Aluminum, Copper, Steel Melting Application for foundry
Energy consumption: 520-600 kwh/t
Capacity varies from 100kg to 50000kg

The Aluminum Shell  Induction Melting Furnace with the varies function of safety system as belows:

 

Safety  protection of induction melting furnace for steel:
1), The main circuit short circuit protection
2), SCR overvoltage protection
3), Main circuit phase fault protection
4), The main circuit phase loss protection
5), Low water pressure protection
6), SCR over current protection

The Whole Set Aluminum Shell Furnace Overview:

Whole set aluminum sheel furnace

Technical Parameter for the Aluminum shell furnace :

(steel for reference)

 

MODEL Input Voltage
V
Rate Power KW DC Voltage V Working
HZ
Working
V
Capacity Power Consumption
GW-0.05-100/1 380(6 Pulse) 100 500 1000 750 0.05 800
GW-0.15-100/1 380(6 Pulse) 100 500 1000 750 0.15/0.12 820
GW-0.25-160/1 380(6 Pulse) 160 500 1000 750 0.25/0.2 790
GW-0.3-250/1 380(6 Pulse) 250 500 1000 750 0.3 770
GW-0.5-250/1 380(6 Pulse) 250 500 1000 1500 0.5 770
GW-0.75-400/1 380(6 Pulse) 400 500 1000 1500 0.75 770
GW-1-500/1 380(6 Pulse) 500 500 1000 1500 1 750
GW-1-750/1 380/690(6 Pulse) 750 500/880 1000 1500 1 720
GW-1.5-1000/0.5 690(6 Pulse) 1000 880 500 2600 1.5 700
GW-2-1500/0.5 690(6 Pulse) 1500 880 500 2600 2 675
GW-3-2500/0.5 1000(6 Pulse) 2500 1250 500 3200 3 590-640
GW-4-3000/0.5 1000(6 Pulse) 3000 1250 500 3200 4 590-640
GW-5-4000/0.5 1000(12Pulse) 4000 1250 500 3400 5 570-630
GW-10-6000/0.5 1000(12Pulse) 6000 1250 500 3400 10 570-630
GW-15-10000/0.25 1000(24 Pulse) 10000 1250 250 3400 15 550-600
GW-20-12000/0.25 1000(24 Pulse) 12000 1200 250 3400 20 550-600
GW-25-14000/0.25 1000(24 Pulse) 14000 1200 150~200 3400 25 550-600
GW-30-16000/0.2 1000(24 Pulse) 16000 1200 150~200 3400 30 550-600
GW-40-18000/0.2 1000(24 Pulse) 18000 1200 150~200 3400 40 550-600
GW-50-20000/0.2 1000(24 Pulse) 20000 1200 150-200 3400 50 550-600
power-supply-aluminum-shell
Induction heating working principle

Through the three-phase AC power supply through the three-phase bridge rectifier, become adjustable DC power supply, through the reactance filter, filter after losing to the single-phase inverter bridge, Through the pulse control, make single bridge diagonal alternation switch become single-phase 1000hz intermediate frequency current. Resonance circuit is made by induction coil and compensation capacitor composition, and the current to the induction coil .The sensors in metal charge generating vortex, then heated to melting furnace

induction-coil
Main components—induction coil

Induction coil used in type T2 (99.9% purity electrolytic copper), wall thickness ≥ 4.5mm extrusion of rectangular tube in the special die winded, It ensures the coil of the rigid, and also has the most conductive section. According to the ISO431-1981 standards for selection of coil material, reach minimum copper loss and high electromagnetic conversion rate.

Induction coil made of high temperature resistance, high pressure resistance insulating paint, insulation grade reaches H grade. Induction coil before they leave the factory will after 12kg/cm2(Schematic diagram for the water pipe and the induction coil connected)hydraulic pressure test 36 hours and 7000v withstand voltage test, there is absolutely no water leakage phenomenon

aluminum-shell-induction-furnace
Coreless induction furnace aluminum furnace body

Intermediate frequency electric furnace complete sets of equipment is change the frequency of 50HZ alternating current into intermediate frequency(more than 250HZ to 2500HZ),the three-phase alternating current into direct current, after the rectification, the DC power into the adjustable frequency current, Supply consists of a capacitor and an induction coil in the intermediate frequency alternating current flowing, to produce a high density of lines of force in the induction coil, and cut the metal materials filled in the induction coil, in metal materials they will have a great eddy current. It based on the principle of electromagnetic induction heating metal. Use of intermediate frequency power supply establishment of intermediate frequency magnetic field, the ferromagnetic material generated internally induced eddy current and heat to achieve the heating material for the purpose. Intermediate frequency electric furnace uses 250-2500Hz medium frequency power supply for induction heating and melting heat. Intermediate frequency electric furnace for smelting steel, alloy steel, special steel, can also be used for copper, aluminum and other non-ferrous metal smelting and extraction temperature. Equipment has the advantages of small volume, light weight, high efficiency, less power consumption, melt fast temperature rising, the furnace temperature is easy to control, high production efficiency.

My company produces aluminum shell furnace use thickening type high purity aluminum panel, can be used for a long time without deformation, stable.

Consists of low voltage switch(circuit-breaker)、rectifier part、reactor、inverter part and other electronic components.

power-supply

The inverter and rectifier part are made of SCR (also known as the thyristor) and water cooling device. Because of SCR chip size, there is a certain pressure between water cooling device and SCR. At the appropriate pressure, cooling capacity will achieve the best results.

Capacitor box

Consists of outer frame、capacitor、connection copper bar and insulation cushion.

capacitor

Capacitor quantity (capacity) is calculated in each set of equipment. The rated power match with furnace and IF power, it can’t be changed as one pleases. Increase or decrease the capacitor please consult relevant personnel and under the guidance of installation technician.

Contruction of aluminum frame induction furnace
Circular aluminum shell furnace is mainly composed of aluminum shell furnace body. bricks (up). bricks(down). asbestos plate .induction coil. stainless steel screw etc,Furnace with aluminum shell is with low cost, easy for maintenance and observation. But it is inefficient and there’s no shield of electromagnetic radiation.

aluminum-shell-furnace-body1

Closed Water Cooling System Presentation:

 

During the Melting process, the whole system will produce lots heat and make the  power supply and furnace body in high temperature, so we need the water cooling  system to cool the whole set machine down.There are two different types of cooling towers : closed circuit cooling towers, and open circuit cooling towers. Both types of towers serve the same purpose, but the closed circuit cooling towers is recommended.

Notes of using cooling machine
1、Put the cooling machine in the outdoor ventilated place and distance IF machine not more then 20 meters. Put auxiliary machine(stainless steel water tank) indoors.
2、Pipe connection mode: red to red, green to green, yellow to yellow, waterway connecting elbow should not be too much.
3、Water pump it is strictly prohibited to no water running, the direction of flow according to the arrow. Fans on the cooling machine should up blowing.
4、After the completion of pipe connection,first add water to test run for a period of time,check whether there is a connection pipe leakage phenomenon and play the role of washing line. Release the water of copper pipe and stainless steel water tank after normal test run, then inject distilled water to start normal work.
5、Pay attention cooling machine antifreeze in winter, according to the actual situation of adding automotive antifreeze to avoid the pipeline burst.
6、According to the work place conditions, clean spray thrower and heat exchanger tubes regularly. Change the water regularly.

Circuit connection diagram:

closed Cooling system operation show

aluminum-shell-induction-melting-on-site

Alumium Frame Induction Melting Furnace Exported To Indonesia

Model: KGPS-gw-100-150-1

Power: 100KW

Power Supply: 3 phase,380V,6 pulse

Rated frequency:1000Hz

Max capacity : 150kg aluminum

Features:This is the aluminum melting  induction melting furnace ,one one  KGPS technology power  supply two furnace body,which is widely used in the foundry industry.our aluminum melting furnace can reach up to 1.5 ton .

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