DELE ELECTRICAL （HANGZHOU）CO.,LTD

DLH-60 HEAT TREATMENT MACHINE DETAILS

According to the domestic chain heat treatment standard, as well as the customer to provide the chain size, processing methods and technology of heat treatment requirements, my company after years of development, manufacturing and continuous improvement, developed to meet the requirements of large chain heat treatment production technology, USES multiple sets of independent output medium frequency power supply respectively in chain quenching and tempering heat treatment, The quenching and tempering heat treatment process of the chain can be accurately controlled from the aspects of power, frequency, induction area and temperature, so as to adjust the physical properties of the chain in all aspects and make it meet the requirements of high-grade quality chain. The following are the parameters of the device:

1. Main technical parameter requirements of the equipment

1.1 The range of specifications of the chain can be processed: Φ42×146mm, 48×144mm, 48×152mm, 52×172mm, 56×185mm, 60×181mm, 60×198mm mining chain;

1.2 The quenching temperature of the chain is 900℃ ~ 1050℃ (adjusted by power and chain walking speed);

Chain tempering temperature 300℃ ~ 600℃ (adjusted by power and chain speed);

1.3 Heating process of chain heat treatment: quenching preheating, quenching heating/heat preservation, tempering heating and tempering heat preservation are realized by using four sets of medium frequency power supply. Each set of IF power supply adopts DSP industrial computer control, IGBT inverter intelligent series resonant IF power supply;

1.4 The output power and resonant frequency of each intermediate frequency power supply in the complete set of equipment can be adjusted independently, and the frequency of the power supply automatically follows the constant power factor control, the output power factor ≥0.98;

1.5 The whole system adopts industrial computer centralized control, and has convenient and beautiful man-machine interaction interface, and can record and save related processes and operating parameters. The storage time of the key operating parameters of the equipment is ≥12 months, and it can be imported into the computer through the U disk;

1.6 TCP/IP network interface is required in the system, and the network address can be modified manually;

1.7 The ambient temperature, water temperature of inlet water and IGBT temperature in the cabinet of the equipment can be monitored and displayed, and the protection value can be set; The quenching and tempering temperatures of the chain are monitored and recorded in real time by an infrared thermometer.

1.8 The quenching and tempering sensor outlet of the chain is equipped with an infrared temperature measuring probe, which can monitor and record the quenching and tempering temperature in real time;

1.9 Medium frequency power supply has overvoltage, overcurrent, overtemperature, current limit, power limit, IGBT and other protection, above fault protection in Chinese display alarm, and can be recorded and saved;

1.10 When the fluctuation range of three-phase supply voltage is 380V±10%, the constant power output can be guaranteed; In any case, under any load (including no-load and full power), within the rated frequency range, the startup success rate is 100%, and it must have soft start function. Any start and stop of the power supply must ensure that it will not affect the power supply network and adjacent equipment.

1.11 The power supply cabinet and capacitor cabinet of the equipment shall be cooled by a matching closed internal circulation cooling system; The inductor and quenching and tempering cooling water are cooled by open circulating water provided by the user.

1.12 The pollution of equipment harmonics to the power grid conforms to the national standard GB/T14549-93 "Harmonics in Power Quality Public Grid".

II. Technical parameters of medium frequency power cabinet

2.1 Input voltage: three-phase five-wire AC380V± 10% /50Hz±1Hz

2.2 Input power ≥1250KVA

2.2 Output power of intermediate frequency power supply:

A. Quenching preheating medium frequency power supply power: 500KW (5% ~ 100% adjustable)

B. Quenching and heating medium frequency power supply: 300KW (5% ~ 100% adjustable)

C. Tempering preheating medium frequency power supply: 160KW (5% ~ 100% adjustable)

D. tempering insulation medium frequency power supply power: 100KW (5% ~ 100% adjustable)

2.3 Output frequency range: 1 ~ 3KHz (automatic sweep frequency adjustable)

2.4 Power factor: ≥98%

2.5 Cooling mode: enclosed internal circulating water cooling mode

IV. Product overview

Intelligent IGPSZ medium frequency power supply device is used in casting, heat treatment and motor welding industries such as melting, diathermic, quenching, tempering, sintering, welding, heating, etc. The device is controlled by a new generation of digital processing chip (DSP), which has the characteristics of automatic frequency tracking, fast start speed and reliable fault diagnosis. The system adopts the all-solid medium frequency induction heating power supply developed by the new high-power power electronic device IGBT, which is highly efficient and energy saving. It has the following characteristics:

• High efficiency and energy saving, the overall efficiency is 93%;

• Electronic control and monitoring protection system is completely reliable;

• Frequent startup, safe and reliable, 100% success rate of startup;

• The output can be controlled by constant power, constant voltage and constant current;

• Wide range of load adaptation, easy adjustment;

• The main components adopt international famous brands, low maintenance cost;

• Adopt water circulation cooling, good cooling effect;

• Simple operation and easy maintenance.

Five, the principle of the intermediate frequency power supply

he main circuit of the system is mainly composed of four parts: three-phase uncontrollable rectifier unit, single-phase full-bridge inverter unit, transformer transmission unit and resonant induction heating part.

The system control principle diagram is as follows:

5.1 IGPSZ intermediate frequency power main loop

The main loop rectifier of IGPSZ intermediate frequency power supply produced by our company is composed of three-phase full-wave rectifier unit with water-cooled diodes produced by Taiki Semiconductor. The IGPSZ intermediate frequency power inverter bridge is composed of IGBT module produced by Germany Infineon Opek Company and IGBT special driver produced by Switzerland Kangsay Company. It has stable and reliable work, high efficiency and high working frequency.

A. Three-phase full-wave rectifier unit

Three - phase full - bridge rectifier unit is a rectifier circuit composed of six diodes. Because the whole circuit is uncontrollable rectification mode, there will be no chopper modulation for three-phase AC sine wave, so there will be no interference, distortion and harmonic interference to the power grid.

B. Inverter unit

Inverter unit is composed of German Infineon IGBT module. Insulated Gate Bipolar Transistor IGBT(Insulated Gate Bipolar Transistor) It is composed of BJT(bipolar triode) and MOS(insulated gate type field effect tube). It has the advantages of high input impedance of MOSFET and low on-voltage drop of GTR. GTR has lower saturation voltage, higher current-carrying density, but higher driving current. MOSFET driving power is very small, switching speed is fast, but the conduction voltage drop is large, the current-carrying density is small. IGBT combines the advantages of the above two devices, low driving power and low saturation voltage. Suitable for converter systems with DC voltage of 600V and above, such as AC motor, frequency converter, switching power supply, lighting circuit, traction drive and other fields.

5.2 IGPSZ IF power supply power and power factor control

The basic composition of intermediate frequency heating power supply is a simple LC series circuit. When the power frequency of the circuit works at the natural resonance point of the circuit, the system presents a pure resistance characteristic. The input power of the power supply can be maximized into the magnetic field energy stored by the induction coil. This system controlled by DSP real-time tracking the maximum power factor, the power always work in the natural resonance point, power factor can reach more than 98%, at this time, the system output power - the current largest, so which can make the current rapid response, rapid temperature adjustment, greatly reduce the preheating time, but also to maximize efficiency, save a lot of energy. When the power supply frequency is adjusted to the natural resonance point of the circuit, the output current of the power supply depends entirely on the output voltage of the inverter. By controlling the conduction ratio of the inverter unit, the output voltage of the inverter is controlled, and the regulation of input/output power is realized.

5.3 Main controller

The main controller adopts Siemens S7-200 PLC, which is mainly used for the communication between DSP controller and human-computer interaction interface, as well as the processing of the whole system motion quantity, analog quantity and protection signal. The CPU of the PLC is 224XP, integrated 14 input/output 24 digital I/O points, 2 input /1 output a total of 3 analog I/O points, can connect 7 expansion modules, the maximum expansion value to 168 digital I/O points or 38 analog I/O points. PLC has a strong anti-interference and stability, the controller's analog output and PID control can fully meet the needs of the control system.

5.4 DSP Controller

The 32-bit DSP chip of TI Corporation in the United States is used to regulate the voltage of the high frequency power supply by controlling the conduction ratio of the inverter bridge, and the frequency of the power supply is adjusted by controlling the output frequency of the IGBT inverter bridge. The system can realize automatic frequency tracking, set a variety of protection, to ensure the safety of the system, such as system failure, you can carry out sound and light alarm, remind the operator to deal with in time.

Compared with ordinary single-chip microcomputer, DSP has its unique advantages, for example, the single-instruction cycle of 51-series single-chip microcomputer is 2_S; The 80C196KC operation instruction cycle is 125ns. Due to the limitation of speed, it is difficult to realize the perfect output of intermediate frequency power SPWM by using the power supply controlled by single chip microcomputer. TMS320F2808 is designed for motor control, digital power supply, automotive control and advanced sensing applications. It features onboard 128KB flash memory and up to 100MIPS (10ns) 32-bit DSP performance, supports high sampling rate, reduces cycle delay, and has powerful peripheral functions. Faster transient response can be achieved by positioning PWM signal edge with 150PS accuracy or 16bit accuracy. TMS320F2808 has 12 bit /16 pass analog-to-digital converter (ADC), 16 unique PWM channels, key communication interfaces including a variety of CAN, 12C, UART and SPI ports, CAN reduce the cost, while making the system has a strong programmable, easier to update and upgrade.

5.5 HMI touch screen

The purpose of man-machine dialogue is to control the operation of the equipment through the use of man-machine communication terminal, operation control software, so that the entire operation process of the device is simple and clear, the device automatically and intelligently run. Human-machine interaction using touch screen control, stable, reliable, long life, very suitable for the harsh electromagnetic environment of the industrial site