CN107385159A - Energy-saving copper wire drawbench induction annealing equipment - Google Patents

Energy-saving copper wire drawbench induction annealing equipment Download PDF

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Publication number
CN107385159A
CN107385159A CN201710563315.0A CN201710563315A CN107385159A CN 107385159 A CN107385159 A CN 107385159A CN 201710563315 A CN201710563315 A CN 201710563315A CN 107385159 A CN107385159 A CN 107385159A
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Prior art keywords
power
inductor
heating
frequency
coil
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章继名
姚迎国
慈龙杰
瞿峰
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TONGLING CHANGJIANG COPPER CO Ltd
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TONGLING CHANGJIANG COPPER CO Ltd
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/26—Methods of annealing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/34—Methods of heating
    • C21D1/42—Induction heating
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D11/00—Process control or regulation for heat treatments
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/54—Furnaces for treating strips or wire
    • C21D9/56—Continuous furnaces for strip or wire
    • C21D9/562—Details
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/54—Furnaces for treating strips or wire
    • C21D9/56—Continuous furnaces for strip or wire
    • C21D9/60—Continuous furnaces for strip or wire with induction heating
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Induction Heating (AREA)

Abstract

The present invention provides a kind of energy-saving copper wire drawbench induction annealing equipment, treats processing component using inductor and is heated, inductor realizes heated at high speed using electromagnetic induction heating coil；Electromagnetic induction heating coil uses solid state UHF induction heating power, and the solid state UHF induction heating power uses E class inverter structures, and switching device uses single tube or two-tube power device.This programme uses a kind of novel E class inverter structures, and switching device uses single tube or two-tube power device, drastically increases channel frequency, and reduces devices switch loss.(2) load coil：Using electromagnetic induction heating, the thermal efficiency of heating is drastically increased.

Description

Energy-saving copper wire drawbench induction annealing equipment
Technical field
The present invention relates to copper wire drawbench induction annealing apparatus field, more particularly to a kind of energy-saving copper wire drawbench sensing Annealing device.
Background technology
Because copper wires cable is low compared with aluminum electric wire resistance, power consumption is few, makes the use range of copper wires cable Further expand.Tongling is the main Copper Processing Industry base in China, builds copper bar wire drawing production project, has advantageous bar Part and the wide market space.
China's copper processing industry equipment advanced and backward technology is simultaneously deposited, by the continuous carry out technological improvement of existing enterprise, hair Exhibition is adapted to China's situation, has the key technology of China's characteristic, is the key point that China's copper processing industry is full of competitive strength.
The developments one of copper processing techniques are to change cooked mode in the world at present, heat of compression processing space, realize copper Material produces continuous production from raw material to finished product, while improves and development heating technique, so as to further save metal consumption, Energy resource consumption, discharge is reduced, it is nuisanceless to reach production.
The continuous high speed annealing of copper wire drawbench mainly use contact electric resistance annealing, and this annealing way needs are with leading Electric carbon brush（There is the carbon brush of size as tens cigarette cases on one electrode wheel）, copper（Aluminium）Electric current on row is transferred to electrode wheel On, by larger resistance when rotating electrode wheel, consume big energy.Produce fire between monofilament and electrode wheel sometimes simultaneously , there is surface oxidation, influences the surface quality of monofilament, and be also easy to produce fracture of wire phenomenon in flower.
Mainly had the advantage that using induction type annealing：The transmission electric current such as brush is not needed to monofilament, it is suffered during work Resistance it is smaller, annealing efficiency is higher（Power consumption deficiency anneal or the half of heat pipe-type annealing, efficiency is by original 30% Left and right brings up to 65% ~ 75%）；No-spark, copper cash non-oxidation is realized, improve annealing quality；Maintenance rate is reduced, reduces maintenance expense With；Annealing speed can be realized from motion tracking；Environment is not almost polluted.
Although induction heating technique is used widely in smelting furnace, sheet material, copper pipe etc. heat and quench at present, Also in the starting stage, technical difficult points are heated at high speed and hyperfrequency solid-state sense for application in the small line footpath wire rod heating of high speed Answer the development of heating power supply.Firing equipment is also monomer-type simultaneously, develops the wire-drawing equipment of integral type induction annealing, is had wide Market prospects.
The content of the invention
It is an object of the invention to provide a kind of energy-saving copper wire drawbench induction annealing equipment, asked with solving above-mentioned technology Topic.
The present invention using following technical scheme in order to solve the above technical problems, realized：
A kind of energy-saving copper wire drawbench induction annealing equipment, it is characterised in that：
Processing component is treated using inductor to be heated, inductor realizes heated at high speed using electromagnetic induction heating coil；
Electromagnetic induction heating coil uses solid state UHF induction heating power, and the solid state UHF induction heating power uses E class inverter structures, switching device use single tube or two-tube power device.
Preferably, solid state UHF induction heating power is made up of rectifying part, chop section, Converting Unit, composition Inverter circuit, direct current is converted into high frequency induction current.
Preferably, the design of the electromagnetic induction heating coil：
（1）The depth of current penetration
Induced-current penetrates into the depth of heating object：
（m）（1）
In formula：Δ be CURRENT DISTRIBUTION bandwidth, unit cm；
ρFor the resistivity of metal, unit Ω m；
The resistivity of copper isρ=1.9×10-8Ω·m；
μFor the relative permeability of metal, unit H/m, the magnetic conductivity of copperμ=1；
f For power frequency, unit Hz；
The 1/ of surface current density is reduced to away from vortex density at the Δ of surfacee , i.e. 36.8 %, it is defined as the depth of current penetration；In electricity Flow the power that metal cylinder absorbs in the range of the depth of penetration and absorb the 86.5% of general power for it；Therefore, Δ becomes heats for selection The important parameter of frequency, it directly affects the distribution of heating-up temperature；
Obtained by the relation on cylindrical conductor effectively between zone of heating and frequency, the limiting value of heat penetration is 0.4D2, D2For quilt Heat the diameter of copper cash；
Relation between metallic resistance rate and temperature：
In formula：ρ 0 It is metal stock 00Resistivity during C, α temperature-coefficient of electrical resistances,ρFor resistance of the metal when temperature is t Rate；
Copperρ 0 =0.016×10-6Ω m, take integral meanρ=0.05×10-6Ω m, α=4.30 × 10-3；
（2）Induction heating current frequency
When sensing heating cylindrical workpiece, due to kelvin effect, only surface can be rapidly heated, and core then needs to pass by heat Effect is led, internally low-temperature space conducts heat from surface high-temp area, thus temperature rise is slow；The temperature difference at surface and center Δ T tables Show；
Calculating shows that the ratio being heated between the diameter of copper cash and the depth of penetration of heating reachesWhen, add The electrical efficiency of hot stove reach the limit values more than 90%, it is possible thereby to obtain the lower limit of power frequency；Source current frequency is got over Height, effective zone of heating are 0.4D by the limiting value of heat penetration with regard to smaller2, can be in the hope of the higher limit of power frequency；Comprehensive sense Relation between electrical efficiency, radial temperature difference and the frequency that should heat, frequency selection are selected by formula below：
（2）
Wherein；
（3）The efficiency and power of inductor
The power that power network is conveyed to induction heating equipment includes two parts：A part is electric power system（Medium frequency converter, conflux Row, capacitor for electric induction heating system etc.）Power loss；Another part is electrical loss in inductor coil, thermal losses and for blank The volume power P of the mean effective power of heating, referred to as medium frequency converter；
The wasted power of Δ P1 inductor coils；General power in P2 blanks；ΔPTPass through the heat loss work(of inductor thermal insulation layer Rate；PTThe mean effective power of blank heating；
The total efficiency of inductor is defined as,The electrical efficiency of inductor is defined as,It is defined as the thermal efficiency of inductor；
（3）
Then have
（4）
The mean effective power of blank heating, the power for being also inductor are：
665.523W （5）
In formula：The mean specific heat of C blanks, kJ/（kg·0C）, the mean specific heat of copper is 0.471；
Δ T is the temperature rise of furnace charge；
M be furnace charge quality, kg；
T heat times, s；
N=M/t is productivity ratio, kg/s；
It is electrical efficiency for the efficiency of inductorAnd the thermal efficiencyProduct；
Copper heating furnace electrical efficiency=0.40 ~ 0.45, the thermal efficiency=0.90 ~ 0.92, gross efficiency η=0.3 ~ 0.40；
（4）The most short heat time
Reach the radial temperature difference of technique permission within the time as short as possible；The most short heat time is represented with following formula：
（6）
In formula：t K To ensure ΔΤ = T 0 - T x When the most short heat time, s；
,For effective zone of heating；
WhenWhen, substitute into, andWhen, then substitute into；
T 0For surface temperature, 0C；
T x Centered on temperature,0C；
AndT 0 - T x = Δ T For radial temperature difference；
a=λ/ cγReferred to as temperature diffusivity；WhereinλFor thermal conductivity factor, W/ (m0C)； c For specific heat capacity, J/(kg0C) ；γFor density, copper density is 8.9 × 10-3kg/ dm3；
D 2 = 2 R 2； tFor heat time, s；
S is auxiliary function；Function S（α, 1）With S（α, 0）；
（5）Induction coil appearance and size
The key dimension of induction coil is its internal diameterD 1And lengtha 1；
1）Internal coil diameterD 1Determination
The electrical efficiency of coil withD 1 /D 2The increase of value and decline；By stove gross efficiency and η withD 1 /D 2Relation curve understand, The gross efficiency of stove has a peak value, as optimum value；WhenD 1 / D 2≈1.4~1.When 8, gross efficiency is maximum；As rational choosing Use scope；
2）The length of coila 1
For continuous-type furnace, its value is determined as the following formula：
（m）（7）
In formula：v For charging movement speed, m/s；
3）The number of turn of inductor
（8）
In formula：U g The terminal voltage of-inductor, V；
P g The input power of-inductor, kW；
4）Electric current and voltage in sensing
（A）
（V）（9）
In formula：The impedance of z-inductor；
The conversion reactance of-blank；
The heat loss of-water cooling guide rail；
5）Compensate capacitor for electric induction heating system capacityQ C
kVar
kVar（10）；
D22、D11The respectively external diameter and internal diameter of hollow cylinder blank；D1For inductor coil internal diameter；
a 2For hollow cylinder charge length；a 1For inductor coil length；
Preferably, the design of the solid state UHF induction heating power：
Using the two-tube DC/AC SHF resonances converter of E classes, hyperfrequency induction heating power is reached 1,000,000 more than MHz, use It is heat-treated with the quenching of superfine type wire or ultra-thin steel band of model or annealing etc.；Due to the parasitism electricity under the conditions of megahertz level on circuit Sense and parasitic capacitance be can not ignore, and the switching loss of power device is considerable, and sensing heating load is varied with temperature and changed The reason such as bigger so that classical conventional inverter topology has significant limitation in megahertz level sensing heating application, therefore The topology research of megahertz level inverter is the emphasis of the invention research.The two-tube full-bridge inverting topology that this programme proposes can have Stray capacitance and stray inductance equal distribution parameter on effect ground absorption circuit, and switching device is ZVT during work, greatly Ground reduces the switching loss of device, and the input of inverter adds high frequency smoothing reactor, the topology is had current mode The advantages of inverter and voltage source inverter, so that the limitation of the no dead time of conducting of two switching tubes, therefore the topology Compare and be adapted to megahertz level hyperfrequency sensing heating.
The E class DC/ AC converters of the two-tube DC/AC SHF resonances converter of E classes, using two pipes alternately work in parallel Make.
Operation principle：
Full-bridge type controlled resonant converter is made up of 4 power switch pipes, half bridge resonant converter also with two power switch pipes, And E class DC/ AC converters are then single tube work, its feature is to choose appropriate load resonant network parameter, makes switching tube In optimum Working, i.e., when switching tube is turned on or off, only after the voltage or electric current of device are reduced to zero, can just lead On-off is opened, and is avoided in switching device while is produced big voltage or electric current, reduces device power consumption during switch conversion.For The power of inverter is improved, reduces single tube capacity, E class DC/ AC converters can use two pipe parallel connection alternations.
Alternating voltage by it is single-phase can not control rectifying circuit be converted to DC voltage, power is carried out by DC chopper circuit Regulation, current detecting and voltage detection signal are converted into power detection signal by analog multiplier, and level demand signal enters Row compares, and its deviation is adjusted by PID regulator, PWM output pulse width is controlled, so as to change DC chopper circuit Power output, form power closed-loop control.PWM phase-shift controllers produce high frequency trigger pulse, pass through drive circuit driving power MOSFET conducting and shut-off, it is high-frequency ac voltage by DC voltage inversion, is coupled by high frequency transformer, be output to sense Device is answered to load.Power MOSFET inverters use the two-tube DC/AC resonant cavity enhanced photodetectors of E classes in figure.
3rd, induction heating power main circuit design
The output voltage of chopper circuit is controlled by the width of controlling switch pipe IGBT driving pulses.Inverter circuit uses E The two-tube alternation formula DC/AC hyperfrequency resonance inverters of class.In order to improve the power output of inverter, reduce single power MOSFET capacity, two power MOSFET parallel connection alternations are used in inverter circuit, are not so increasing single power In the case of MOSFET capacity, with the power MOSFET of two identical capacity, the power output of inverter can improve by about one time. The MOSFET parallel connection alternations of two other power, under conditions of the identical output frequency of inverter, the frequency of drive circuit can be made Rate drops to half during single tube work, i.e., when the output frequency of inverter is 2MHz, as long as the frequency 1MHz of drive circuit, Reduce the rapidity requirement to drive circuit.
Circuit parameter calculation：If the output frequency of high frequency electric source isf, then resonant frequencyf 0 is equal tof Meet such as ShiShimonoseki System：
（11）
Two formulas are drawn more than：
（12）
Take C simultaneously1=C0；
4th, control circuit
Inverter control circuit uses MC34067 high speed PWM nonshared control units.The characteristics of circuit is output driving pulsed operation Frequency can reach 2MHz, and inside uses totem recommending output mode, and peak inrush current reaches 1.5A.
Power and current regulation use double-closed-loop control, and power and current regulator use pi regulator.Circuit is simultaneously There is provided frequency tracking circuit.
The technical scheme of the invention is carried out primarily directed to the annealing device of LH450/13 sliding type aluminums (copper) big drawing machine group Transformation, research and development induction annealing device substitute the annealing device of the contact brush transmission of the equipment, can be used for Φ 9.5mm aluminium Bar is drawn into Φ 1.8mm~Φ 4.5mm aluminum steels, or Φ 8mm copper bars are drawn on the big drawing machine of Φ 1.2mm~Φ 4.0mm copper cash. Big frequency range can also be used on Medium drawing mach ine and small machine drawing equipment, and independent product can be used for making independent induction power supply, use The metal hot-working such as sheet material annealing, quenching in small line footpath wire rod, thin size.
The beneficial effects of the invention are as follows：
(1) hyperfrequency inverter：Small sized metallic material heat treatment induction heating power frequency must 1MHz with On, current induction heating power DC/AC inverters typically use bridge-type resonant transform circuit, but by semiconductor power device The limitation of switching frequency, plus dead time and the demand of safety allowance, frequency is difficult to bring up to several MHz.This programme uses one The novel E class inverter structures of kind, switching device use single tube or two-tube power device, drastically increase channel frequency, and Reduce devices switch loss.
(2) load coil：Using electromagnetic induction heating, the thermal efficiency of heating is drastically increased.
Brief description of the drawings
Fig. 1 is function S（α, 1）With S（α, 0）；
Fig. 2 is load coil dimensional drawing；
Fig. 3 is hyperfrequency induction heating power system block diagram；
Fig. 4 is hyperfrequency solid-state power source main circuit diagram；
Fig. 5 is inverter output voltage current waveform.
Embodiment
In order that the technical means, the inventive features, the objects and the advantages of the present invention are easy to understand, tie below Specific embodiment is closed, the present invention is expanded on further, but following embodiments are only the preferred embodiments of the present invention, and it is not all. Based on the embodiment in embodiment, those skilled in the art obtain other realities on the premise of creative work is not made Example is applied, belongs to protection scope of the present invention.Experimental method in following embodiments, it is conventional method unless otherwise specified, Material used, reagent etc., unless otherwise specified, are commercially obtained in following embodiments.
A kind of energy-saving copper wire drawbench induction annealing equipment, processing component is treated using inductor and heated, sensed Device realizes heated at high speed using electromagnetic induction heating coil；
Electromagnetic induction heating coil uses solid state UHF induction heating power, and the solid state UHF induction heating power uses E class inverter structures, switching device use single tube or two-tube power device.
Solid state UHF induction heating power is made up of rectifying part, chop section, Converting Unit, the inversion electricity of composition Road, direct current is converted into high frequency induction current.
The design of the electromagnetic induction heating coil：
（1）The depth of current penetration
Induced-current penetrates into the depth of heating object：
（m）（1）
In formula：Δ be CURRENT DISTRIBUTION bandwidth, unit cm；
ρFor the resistivity of metal, unit Ω m；
The resistivity of copper isρ=1.9×10-8Ω·m；
μFor the relative permeability of metal, unit H/m, the magnetic conductivity of copperμ=1；
f For power frequency, unit Hz；
The 1/ of surface current density is reduced to away from vortex density at the Δ of surfacee , i.e. 36.8 %, it is defined as the depth of current penetration；In electricity Flow the power that metal cylinder absorbs in the range of the depth of penetration and absorb the 86.5% of general power for it；Therefore, Δ becomes heats for selection The important parameter of frequency, it directly affects the distribution of heating-up temperature；
Obtained by the relation on cylindrical conductor effectively between zone of heating and frequency, the limiting value of heat penetration is 0.4D2, D2For quilt Heat the diameter of copper cash；
Relation between metallic resistance rate and temperature：
In formula：ρ 0 It is metal stock 00Resistivity during C, α temperature-coefficient of electrical resistances,ρFor resistance of the metal when temperature is t Rate；
Copperρ 0 =0.016×10-6Ω m, take integral meanρ=0.05×10-6Ω m, α=4.30 × 10-3；
（2）Induction heating current frequency
When sensing heating cylindrical workpiece, due to kelvin effect, only surface can be rapidly heated, and core then needs to pass by heat Effect is led, internally low-temperature space conducts heat from surface high-temp area, thus temperature rise is slow；The temperature difference at surface and center Δ T tables Show；
Calculating shows that the ratio being heated between the diameter of copper cash and the depth of penetration of heating reachesWhen, add The electrical efficiency of hot stove reach the limit values more than 90%, it is possible thereby to obtain the lower limit of power frequency；Source current frequency is got over Height, effective zone of heating are 0.4D by the limiting value of heat penetration with regard to smaller2, can be in the hope of the higher limit of power frequency；Comprehensive sense Relation between electrical efficiency, radial temperature difference and the frequency that should heat, frequency selection are selected by formula below：
（2）
Wherein；
（3）The efficiency and power of inductor
The power that power network is conveyed to induction heating equipment includes two parts：A part is electric power system（Medium frequency converter, conflux Row, capacitor for electric induction heating system etc.）Power loss；Another part is electrical loss in inductor coil, thermal losses and for blank The volume power P of the mean effective power of heating, referred to as medium frequency converter；
The wasted power of Δ P1 inductor coils；General power in P2 blanks；ΔPTPass through the heat loss work(of inductor thermal insulation layer Rate；PTThe mean effective power of blank heating；
The total efficiency of inductor is defined as,The electrical efficiency of inductor is defined as,It is defined as the thermal efficiency of inductor；
（3）
Then have
（4）
The mean effective power of blank heating, the power for being also inductor are：
665.523W （5）
In formula：The mean specific heat of C blanks, kJ/（kg·0C）, the mean specific heat of copper is 0.471；
Δ T is the temperature rise of furnace charge；
M be furnace charge quality, kg；
T heat times, s；
N=M/t is productivity ratio, kg/s；
It is electrical efficiency for the efficiency of inductorAnd the thermal efficiencyProduct；
Copper heating furnace electrical efficiency=0.40 ~ 0.45, the thermal efficiency=0.90 ~ 0.92, gross efficiency η=0.3 ~ 0.40；
（4）The most short heat time
Reach the radial temperature difference of technique permission within the time as short as possible；The most short heat time is represented with following formula：
（6）
In formula：t K To ensure ΔΤ = T 0 - T x When the most short heat time, s；
,For effective zone of heating；
WhenWhen, substitute into, andWhen, then substitute into；
T 0For surface temperature, 0C；
T x Centered on temperature,0C；
AndT 0 - T x = Δ T For radial temperature difference；
a=λ/ cγReferred to as temperature diffusivity；WhereinλFor thermal conductivity factor, W/ (m0C)； c For specific heat capacity, J/(kg0C) ；γFor density, copper density is 8.9 × 10-3kg/ dm3；
D 2 = 2 R 2； tFor heat time, s；
S is auxiliary function；Function S（α, 1）With S（α, 0）, as shown in Figure 1；
（5）Induction coil appearance and size
The key dimension of induction coil is its internal diameterD 1And lengtha 1；
1）Internal coil diameterD 1Determination
The electrical efficiency of coil withD 1 /D 2The increase of value and decline；By stove gross efficiency and η withD 1 /D 2Relation curve understand, The gross efficiency of stove has a peak value, as optimum value；WhenD 1 / D 2≈1.4~1.When 8, gross efficiency is maximum；As rational choosing Use scope；
2）The length of coila 1
For continuous-type furnace, its value is determined as the following formula：
（m）（7）
In formula：v For charging movement speed, m/s；
3）The number of turn of inductor
（8）
In formula：U g The terminal voltage of-inductor, V；
P g The input power of-inductor, kW；
4）Electric current and voltage in sensing
（A）
（V）（9）
In formula：The impedance of z-inductor；
The conversion reactance of-blank；
The heat loss of-water cooling guide rail；
5）Compensate capacitor for electric induction heating system capacityQ C
kVar
kVar（10）；
As shown in Fig. 2 D22、D11The respectively external diameter and internal diameter of hollow cylinder blank；D1For inductor coil internal diameter；a 2For sky Heart cylindrical blank length；a 1For inductor coil length；
The design of the solid state UHF induction heating power：
Using the two-tube DC/AC SHF resonances converter of E classes, hyperfrequency induction heating power is reached 1,000,000 more than MHz, use It is heat-treated with the quenching of superfine type wire or ultra-thin steel band of model or annealing etc.；Due to the parasitism electricity under the conditions of megahertz level on circuit Sense and parasitic capacitance be can not ignore, and the switching loss of power device is considerable, and sensing heating load is varied with temperature and changed The reason such as bigger so that classical conventional inverter topology has significant limitation in megahertz level sensing heating application, therefore The topology research of megahertz level inverter is the emphasis of the invention research.The two-tube full-bridge inverting topology that this programme proposes can have Stray capacitance and stray inductance equal distribution parameter on effect ground absorption circuit, and switching device is ZVT during work, greatly Ground reduces the switching loss of device, and the input of inverter adds high frequency smoothing reactor, the topology is had current mode The advantages of inverter and voltage source inverter, so that the limitation of the no dead time of conducting of two switching tubes, therefore the topology Compare and be adapted to megahertz level hyperfrequency sensing heating；
The E class DC/ AC converters of the two-tube DC/AC SHF resonances converter of E classes, using two pipe parallel connection alternations.
Operation principle：
Full-bridge type controlled resonant converter is made up of 4 power switch pipes, half bridge resonant converter also with two power switch pipes, And E class DC/ AC converters are then single tube work, its feature is to choose appropriate load resonant network parameter, makes switching tube In optimum Working, i.e., when switching tube is turned on or off, only after the voltage or electric current of device are reduced to zero, can just lead On-off is opened, and is avoided in switching device while is produced big voltage or electric current, reduces device power consumption during switch conversion.For The power of inverter is improved, reduces single tube capacity, E class DC/ AC converters can use two pipe parallel connection alternations.
In Fig. 3 alternating voltage by it is single-phase can not control rectifying circuit be converted to DC voltage, entered by DC chopper circuit Row power adjusting, current detecting and voltage detection signal are converted into power detection signal by analog multiplier, and power gives Signal is compared, and its deviation is adjusted by PID regulator, controls PWM output pulse width, so as to change DC chopped-wave The power output of circuit, form power closed-loop control.PWM phase-shift controllers produce high frequency trigger pulse, are driven by drive circuit Dynamic power MOSFET conducting and shut-off, is high-frequency ac voltage by DC voltage inversion, is coupled by high frequency transformer, defeated Go out to inductor and load.Power MOSFET inverters use the two-tube DC/AC resonant cavity enhanced photodetectors of E classes in figure.
3rd, induction heating power main circuit design
Fig. 4 is hyperfrequency induction heating power main circuit.Copped wave is controlled by the width of controlling switch pipe IGBT driving pulses The output voltage of circuit.Inverter circuit uses the two-tube alternation formula DC/AC hyperfrequency resonance inverters of E classes.In order to improve The power output of inverter, reduce single power MOSFET capacity, use two power MOSFET in parallel in inverter circuit Alternation, so in the case where not increasing single power MOSFET capacity, with the power MOSFET of two identical capacity, The power output of inverter can improve by about one time.Two other power MOSFET parallel connection alternations, in the identical output of inverter Under conditions of frequency, can make drive circuit frequency drop to single tube work when half, i.e., when the output frequency of inverter is During 2MHz, as long as the frequency 1MHz of drive circuit, reduces the rapidity requirement to drive circuit.
Circuit parameter calculation：If the output frequency of high frequency electric source isf, then resonant frequencyf 0 is equal tof Meet such as ShiShimonoseki System：
（11）
Two formulas are drawn more than：
（12）
Take C simultaneously1=C0；
4th, control circuit
Electric operation control circuit figure is shown in Fig. 3.Inverter control circuit uses MC34067 high speed PWM nonshared control units.The characteristics of circuit is Output driving pulsed operation frequency can reach 2MHz, and inside uses totem recommending output mode, and peak inrush current reaches 1.5A；
Power and current regulation use double-closed-loop control, and power and current regulator use pi regulator.Circuit is set simultaneously Frequency tracking circuit；
5th, inverter output waveforms
Fig. 5 is this programme output voltage and current waveform, and a is the voltage being added on load coil in figure, b resonant capacitances C0 The voltage at both ends, c0 [i] are the current waveform on induction coil.It can be seen that the voltage at heating coil both ends is straight Stream electricity, inverter can export 2MHz ultrahigh-frequency currents, and sine-wave current wave distortion is small, is approximately an ideal waveform.
General principle, principal character and the advantages of the present invention of the present invention has been shown and described above.The technology of the industry For personnel it should be appreciated that the present invention is not limited to the above embodiments, that described in above-described embodiment and specification is only the present invention Preference, be not intended to limit the present invention, without departing from the spirit and scope of the present invention, the present invention also have it is various Changes and improvements, these changes and improvements all fall within the protetion scope of the claimed invention.The claimed scope of the invention is by institute Attached claims and its equivalent thereof.

Claims (4)

  1. A kind of 1. energy-saving copper wire drawbench induction annealing equipment, it is characterised in that：
    Processing component is treated using inductor to be heated, inductor realizes heated at high speed using electromagnetic induction heating coil；
    Electromagnetic induction heating coil uses solid state UHF induction heating power, and the solid state UHF induction heating power uses E class inverter structures, switching device use single tube or two-tube power device.
  2. 2. energy-saving copper wire drawbench induction annealing equipment according to claim 1, it is characterised in that：Solid state UHF sense Answer heating power supply to be made up of rectifying part, chop section, Converting Unit, the inverter circuit of composition, direct current is converted into high frequency Induced-current.
  3. 3. energy-saving copper wire drawbench induction annealing equipment according to claim 1, it is characterised in that：The electromagnetic induction The design of heating coil：
    （1）The depth of current penetration
    Induced-current penetrates into the depth of heating object：
    （m）（1）
    In formula：Δ be CURRENT DISTRIBUTION bandwidth, unit cm；
    ρFor the resistivity of metal, unit Ω m；
    The resistivity of copper isρ=1.9×10-8Ω·m；
    μFor the relative permeability of metal, unit H/m, the magnetic conductivity of copperμ=1；
    f For power frequency, unit Hz；
    The 1/ of surface current density is reduced to away from vortex density at the Δ of surfacee , i.e. 36.8 %, it is defined as the depth of current penetration；In electricity Flow the power that metal cylinder absorbs in the range of the depth of penetration and absorb the 86.5% of general power for it；Therefore, Δ becomes heats for selection The important parameter of frequency, it directly affects the distribution of heating-up temperature；
    Obtained by the relation on cylindrical conductor effectively between zone of heating and frequency, the limiting value of heat penetration is 0.4D2, D2For quilt Heat the diameter of copper cash；
    Relation between metallic resistance rate and temperature：
    In formula：ρ 0 It is metal stock 00Resistivity during C, α temperature-coefficient of electrical resistances,ρFor resistivity of the metal when temperature is t；
    Copperρ 0 =0.016×10-6Ω m, take integral meanρ=0.05×10-6Ω m, α=4.30 × 10-3；
    （2）Induction heating current frequency
    When sensing heating cylindrical workpiece, due to kelvin effect, only surface can be rapidly heated, and core then needs to pass by heat Effect is led, internally low-temperature space conducts heat from surface high-temp area, thus temperature rise is slow；The temperature difference at surface and center Δ T tables Show；
    Calculating shows that the ratio being heated between the diameter of copper cash and the depth of penetration of heating reachesWhen, heating The electrical efficiency of stove reach the limit values more than 90%, it is possible thereby to obtain the lower limit of power frequency；Source current frequency is higher, Effective zone of heating is 0.4D by the limiting value of heat penetration with regard to smaller2, can be in the hope of the higher limit of power frequency；Integrated sensor cable Relation between the electrical efficiency of heating, radial temperature difference and frequency, frequency selection are selected by formula below：
    （2）
    Wherein；
    （3）The efficiency and power of inductor
    The power that power network is conveyed to induction heating equipment includes two parts：A part is the power loss of electric power system；Other one Part is electrical loss, thermal losses and the mean effective power for blank heating in inductor coil, referred to as intermediate frequency frequency conversion The volume power P of device；
    The wasted power of Δ P1 inductor coils；General power in P2 blanks；ΔPTPass through the heat loss work(of inductor thermal insulation layer Rate；PTThe mean effective power of blank heating；
    The total efficiency of inductor is defined as,The electrical efficiency of inductor is defined as,It is defined as the thermal efficiency of inductor；
    （3）
    Then have
    （4）
    The mean effective power of blank heating, the power for being also inductor are：
    665.523W （5）
    In formula：The mean specific heat of C blanks, kJ/（kg·0C）, the mean specific heat of copper is 0.471；
    Δ T is the temperature rise of furnace charge；
    M be furnace charge quality, kg；
    T heat times, s；
    N=M/t is productivity ratio, kg/s；
    It is electrical efficiency for the efficiency of inductorAnd the thermal efficiencyProduct；
    Copper heating furnace electrical efficiency=0.40 ~ 0.45, the thermal efficiency=0.90 ~ 0.92, gross efficiency η=0.3 ~ 0.40；
    （4）The most short heat time
    Reach the radial temperature difference of technique permission within the time as short as possible；The most short heat time is represented with following formula：
    （6）
    In formula：t K To ensure ΔΤ = T 0 - T x When the most short heat time, s；
    ,For effective zone of heating；
    WhenWhen, substitute into, andWhen, then substitute into；
    T 0For surface temperature, 0C；
    T x Centered on temperature,0C；
    AndT 0 - T x = Δ T For radial temperature difference；
    a=λ/ cγReferred to as temperature diffusivity；WhereinλFor thermal conductivity factor, W/ (m0C)； c For specific heat capacity, J/(kg0C) ；γFor density, copper density is 8.9 × 10-3kg/ dm3；
    D 2 = 2 R 2； tFor heat time, s；
    S is auxiliary function；Function S（α, 1）With S（α, 0）；
    （5）Induction coil appearance and size
    The key dimension of induction coil is its internal diameterD 1And lengtha 1；
    1）Internal coil diameterD 1Determination
    The electrical efficiency of coil withD 1 /D 2The increase of value and decline；By stove gross efficiency and η withD 1 /D 2Relation curve understand, stove The gross efficiency of son has a peak value, as optimum value；WhenD 1 / D 2≈1.4~1.When 8, gross efficiency is maximum；Selected as rational Scope；
    2）The length of coila 1
    For continuous-type furnace, its value is determined as the following formula：
    （m）（7）
    In formula：v For charging movement speed, m/s；
    3）The number of turn of inductor
    （8）
    In formula：U g The terminal voltage of-inductor, V；
    P g The input power of-inductor, kW；
    4）Electric current and voltage in sensing
    （A）
    （V）（9）
    In formula：The impedance of z-inductor；
    The conversion reactance of-blank；
    The heat loss of-water cooling guide rail；
    5）Compensate capacitor for electric induction heating system capacityQ C
    kVar
    kVar（10）；
    D22、D11The respectively external diameter and internal diameter of hollow cylinder blank；D1For inductor coil internal diameter；
    a 2For hollow cylinder charge length；a 1For inductor coil length.
  4. 4. energy-saving copper wire drawbench induction annealing equipment according to claim 1, it is characterised in that：The solid-state superelevation The design of frequency induction heating power：
    Using the two-tube DC/AC SHF resonances converter of E classes, hyperfrequency induction heating power is set to reach 1,000,000 more than MHz, E classes The E class DC/ AC converters of two-tube DC/AC SHF resonances converter, using two pipe parallel connection alternations.
CN201710563315.0A 2017-07-12 2017-07-12 Energy-saving copper wire drawbench induction annealing equipment Pending CN107385159A (en)

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Application publication date: 20171124