CN114540608A - Heavy rail steel electromagnetic induction heating device, control method thereof and heating system - Google Patents
Heavy rail steel electromagnetic induction heating device, control method thereof and heating system Download PDFInfo
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- CN114540608A CN114540608A CN202210180137.4A CN202210180137A CN114540608A CN 114540608 A CN114540608 A CN 114540608A CN 202210180137 A CN202210180137 A CN 202210180137A CN 114540608 A CN114540608 A CN 114540608A
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- induction heater
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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
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/04—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for rails
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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
- C21D1/06—Surface hardening
- C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
- C21D1/10—Surface hardening by direct application of electrical or wave energy; by particle radiation by electric induction
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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
- C21D11/00—Process control or regulation for heat treatments
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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
- C21D2221/00—Treating localised areas of an article
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- 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
Abstract
The invention discloses a heavy rail steel electromagnetic induction heating device, a control method and a heating system thereof, wherein the heating device comprises a device body, a first electromagnetic induction heater, a second electromagnetic induction heater, a third electromagnetic induction heater, a first temperature sensor, a second temperature sensor, a third temperature sensor, a control module and a power supply module; the temperature sensors are used for detecting real-time temperatures of different parts of the heavy rail steel, the control module calculates the operation power of the corresponding electromagnetic induction heater according to the target temperatures of the different parts of the heavy rail steel and the corresponding real-time temperatures, and then the corresponding electromagnetic induction heater is controlled to operate at the operation power, so that the aim of heating the different parts of the heavy rail steel to the corresponding target temperatures is fulfilled. The invention can realize the on-line heating of different positions of the heavy rail steel according to the requirements and can meet the different heat treatment requirements of each part of the heavy rail steel.
Description
Technical Field
The invention belongs to the technical field of heavy rail induction heating equipment, and particularly relates to a heavy rail steel electromagnetic induction heating device, a control method thereof and a heating system.
Background
With the increase of railway carrying capacity, higher requirements are also put on the performance quality of the steel rail. In order to improve the service life and the performance of the heavy rail, the steel rail needs to be subjected to heat treatment so as to improve the heat treatment strength of the steel rail, and further meet the rapid development requirements of railways and mineral transportation. The quality and performance of the heat treatment of the steel rail greatly depend on heating equipment and temperature control precision related to the heat treatment process.
The section of the heavy rail belongs to a special-shaped section, and the difference of the heat dissipation areas of all parts of the section is large, so that the cooling speed is easy to be inconsistent, the temperature distribution of the heavy rail is uneven, and the thermal deformation and the thermal stress are caused. In addition, the complexity of stress on each part of the heavy rail steel and the depth of the induction heating hardening layer required by different positions are different, so that the required heat treatment temperature is different, for example, the heavy rail head is the part mainly stressed and worn, and the induction heater is required to fully ensure the heat penetration and heat soaking of the rail head. The heating device is not reasonable in heat treatment, and although local parts are subjected to heat treatment, other parts are overheated or over-burnt, so that the internal structure of the steel rail is damaged.
At present, the electromagnetic heating process is applied to heating the heavy rail steel integrally, for example, chinese patent document No. CN109207681A entitled split type heavy rail induction heater cannot perform different deep heating treatments of the hardened layer for different positions of the heavy rail steel.
Disclosure of Invention
The invention aims to provide an electromagnetic induction heating device for heavy rail steel, a control method and a heating system thereof, and aims to solve the problem that the prior art cannot meet different heat treatment requirements of various parts of the heavy rail steel.
The invention solves the technical problems through the following technical scheme: an electromagnetic induction heating device for heavy rail steel, comprising:
a device body;
the first electromagnetic induction heater is arranged on the device body and used for heating the heavy rail head;
the second electromagnetic induction heater is arranged on the device body and used for heating the rail web of the heavy rail;
the third electromagnetic induction heater is arranged on the device body and used for heating the rail bottom of the heavy rail;
the first temperature sensor is used for monitoring the temperature of the heavy rail steel rail head;
the second temperature sensor is used for monitoring the temperature of the rail web of the heavy rail steel;
the third temperature sensor is used for monitoring the rail bottom temperature of the heavy rail;
the control module is respectively electrically connected with the first electromagnetic induction heater, the second electromagnetic induction heater, the third electromagnetic induction heater, the first temperature sensor, the second temperature sensor and the third temperature sensor;
and the power supply module is respectively and electrically connected with the first electromagnetic induction heater, the second electromagnetic induction heater, the third electromagnetic induction heater, the first temperature sensor, the second temperature sensor, the third temperature sensor and the control module.
Further, the first electromagnetic induction heater comprises a U-shaped iron core matched with the heavy rail head in shape, and induction coils respectively arranged on two sides and the top of the U-shaped iron core.
Further, the second electromagnetic induction heater has two and locates respectively the both sides of heavy rail web, every the second electromagnetic induction heater all includes the iron core and locates two induction coil on the iron core.
Further, the third electromagnetic induction heater comprises an E-shaped iron core and induction coils respectively arranged in the two grooves of the E-shaped iron core.
Furthermore, a sliding groove is formed in the corresponding position of the device body, a guide rail matched with the corresponding sliding groove is arranged on the first electromagnetic induction heater, a guide rail matched with the corresponding sliding groove is arranged on the second electromagnetic induction heater, a guide rail matched with the corresponding sliding groove is arranged on the third electromagnetic induction heater, and the first electromagnetic induction heater, the second electromagnetic induction heater and the third electromagnetic induction heater are arranged at the corresponding positions of the device body through the respective guide rails and the corresponding sliding grooves.
Furthermore, end plates are arranged on the front side and the back side of the device body, and a closed cavity is formed by the device body and the end plates; an inlet or an outlet matched with the shape of the heavy rail steel is formed in the end plate; the first electromagnetic induction heater, the second electromagnetic induction heater and the third electromagnetic induction heater are all provided with a fixed rod, one end of the fixed rod is fixed on the end plate on the front side, and the other end of the fixed rod is fixed on the end plate on the back side; wherein the front surface of the device body refers to the surface of the heavy rail steel entering the device during heating.
Further, the device further comprises a cooling mechanism for cooling the power module and the device body.
The invention also provides a control method of the electromagnetic induction heating device for the heavy rail steel, which comprises the following steps:
respectively acquiring real-time temperature T acquired by a first temperature sensor1The real-time temperature T acquired by the second temperature sensor2And the real-time temperature T acquired by the third temperature sensor3；
According to the real-time temperature T1And a target temperature T10Calculating the operating power P of the first electromagnetic induction heater1According to said real-time temperature T2And a target temperature T20Calculating the operating power P of the second electromagnetic induction heater2According to said real-timeTemperature T3And a target temperature T30Calculating the operating power P of the second electromagnetic induction heater3；
Controlling the first electromagnetic induction heater to have power P1Operation, controlling the second electromagnetic induction heater to have power P2Operating, controlling the third electromagnetic induction heater to have power P3And (5) operating.
Further, the calculation formula of the operating power is as follows:
wherein P is the operating power of the electromagnetic induction heater, T is the real-time temperature collected by the corresponding temperature sensor, and T is the temperature of the electromagnetic induction heater0Corresponding to the target temperature, C is the specific heat capacity of the heavy rail steel, and W is the mass per meter of the heavy rail steel in kg.m-1V is the running speed of the heavy rail steel during heating, and eta is the efficiency of the electromagnetic induction heater.
Furthermore, while controlling the power of the first electromagnetic induction heater, the second electromagnetic induction heater and the third electromagnetic induction heater, the power supply current frequency of the corresponding electromagnetic induction heater is controlled according to the heating requirements of different positions of the heavy rail steel and different depths of the hardened layer.
The invention also provides a heavy rail steel electromagnetic induction heating system, which comprises a plurality of heavy rail steel electromagnetic induction heating devices; and the multiple heavy rail steel electromagnetic induction heating devices are arranged at intervals along a straight line.
Advantageous effects
Compared with the prior art, the invention has the advantages that:
according to the electromagnetic induction heating device for the heavy rail steel, the control method and the heating system thereof, the power of the first electromagnetic induction heater, the power of the second electromagnetic induction heater and the power of the third electromagnetic induction heater are respectively controlled independently or simultaneously according to different heat treatment temperatures needed by the rail head, the rail web and the rail bottom of the heavy rail steel, so that the on-line heating of the heavy rail steel at different positions as required is realized, and different heat treatment requirements of each part of the heavy rail steel can be met; first electromagnetic induction heater, second electromagnetic induction heater and third electromagnetic induction heater can be installed or the selectivity installation simultaneously according to the control by temperature change demand of actual production, have improved the commonality and the convenience of device.
The heating system formed by the multiple heavy rail steel electromagnetic induction heating devices can meet the high-temperature heating requirement of the heavy rail steel, is convenient for system maintenance and reduces the maintenance cost.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only one embodiment of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on the drawings without creative efforts.
FIG. 1 is a schematic structural diagram of an electromagnetic induction heating device for heavy rail steel according to an embodiment of the present invention;
FIG. 2 is a schematic view of the internal structure of the device body according to the embodiment of the present invention;
FIG. 3 is an outline view of an apparatus in an embodiment of the present invention;
FIG. 4 is a front view of an apparatus according to an embodiment of the present invention;
FIG. 5 is a schematic structural view of a first electromagnetic induction heater in an embodiment of the present invention;
FIG. 6 is a schematic diagram of a first electromagnetic induction heater heating a rail head in an embodiment of the invention;
FIG. 7 is a schematic view of a second electromagnetic induction heater heating a rail web according to an embodiment of the present invention;
FIG. 8 is a schematic structural view of a second electromagnetic induction heater in the embodiment of the present invention;
FIG. 9 is a schematic view of a third electromagnetic induction heater heating a rail foot in an embodiment of the invention;
fig. 10 is a schematic structural view of a third electromagnetic induction heater in the embodiment of the invention;
fig. 11 is a magnetic field distribution diagram inside the device body in the embodiment of the present invention, wherein + represents the current inflow, and ● represents the current outflow direction;
FIG. 12 is a prior art magnetic flux/induction coil distribution plot in an embodiment of the present invention;
FIG. 13 is a graph of the position of a prior art induction coil and heavy rail steel in an embodiment of the present invention.
Wherein, 1-a first temperature sensor, 2-heavy rail steel, 3-a second temperature sensor, 4-a power module, 5-a control module, 6-a cooling mechanism, 7-a first electromagnetic induction heater, 701-a U-shaped iron core, 702-induction coils arranged at two sides and the top of the U-shaped iron core, 703-a guide rail of the first electromagnetic induction heater, 704-a fixed rod of the first electromagnetic induction heater, 8-a running direction of the heavy rail steel when heating, 9-a carrier roller, 10-a device body, 101-a chute, 102-a front end plate, 103-a bolt, 11-a second electromagnetic induction heater, 1101-an iron core, 1102-two induction coils arranged on the iron core, 1103-a guide rail of the second electromagnetic induction heater, 1104-a fixed rod of the second electromagnetic induction heater, 12-a third electromagnetic induction heater, 1201-an E-shaped iron core, 1202-induction coils arranged in two grooves of the E-shaped iron core, 1203-a guide rail of the third electromagnetic induction heater, 1204-a fixing rod of the third electromagnetic induction heater, 13-a motor, 14-magnetic lines of force, and 15-the induction coils.
Detailed Description
The technical solutions in the present invention are clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The technical solution of the present application will be described in detail below with specific examples. The following several specific embodiments may be combined with each other, and details of the same or similar concepts or processes may not be repeated in some embodiments.
As shown in fig. 1 and 2, the electromagnetic induction heating apparatus for heavy rail steel provided in this embodiment includes an apparatus body 10, a first electromagnetic induction heater 7, a second electromagnetic induction heater 11, a third electromagnetic induction heater 12, a first temperature sensor 1, a second temperature sensor 3, a third temperature sensor, a control module 5, and a power module 4. The device body 10 is openly and back open-ended box structure, and first electromagnetic induction heater 7 is located the top of box structure and is used for heating 2 railheads of heavy rail steel, and two second electromagnetic induction heaters 11 are located the both sides of box structure respectively and are used for heating 2 rail waists of heavy rail steel, and third electromagnetic induction heater 12 is located the bottom of box structure and is used for heating 2 rail bottoms of heavy rail steel. First temperature sensor 1 locates the entrance of device or openly and is used for detecting the real-time temperature of 2 railheads of heavy rail steel, and second temperature sensor 3 locates the entrance of device or openly and is used for detecting the real-time temperature of 2 rail waists of heavy rail steel, and the entrance of device or openly and be used for detecting the real-time temperature at the bottom of the 2 rail of heavy rail steel are located to third temperature sensor. The control module 5 calculates the operation power of the first electromagnetic induction heater 7 according to the real-time temperature and the target temperature thereof acquired by the first temperature sensor 1, calculates the operation power of the second electromagnetic induction heater 11 according to the real-time temperature and the target temperature thereof acquired by the second temperature sensor 3, calculates the operation power of the third electromagnetic induction heater 12 according to the real-time temperature and the target temperature thereof acquired by the third temperature sensor, and realizes different heat treatment requirements of different parts of the heavy rail steel 2 by controlling the power of each electromagnetic induction heater individually or simultaneously. The power module 4 supplies power to each part of the device. Under the transmission of the motor 13 and the carrier roller 9, the heavy rail steel 2 passes through the electromagnetic induction heating device of the embodiment at a certain speed, and the purpose of heating different parts of the heavy rail steel 2 to corresponding target temperatures is achieved.
As shown in fig. 3 and 4, the front and back of the device body 10 are provided with end plates, and a closed cavity is formed by the device body 10, the front end plate 102 and the back end plate, so that heat generated by the electromagnetic induction heater is enclosed in the device, thereby avoiding heat dissipation and ensuring heating effect; an inlet and an outlet which are matched with the shape of the heavy rail steel 2 are formed in the front end plate 102 and the back end plate, when heating is carried out, the heavy rail steel 2 enters the device from the inlet in the front end plate 102, and then exits the device from the outlet in the back end plate after heating to enter the next device or the heating is completed.
As shown in fig. 5, the first electromagnetic induction heater 7 includes a U-shaped iron core 701 adapted to the shape of the heavy rail steel 2 head, and induction coils 702 respectively disposed on two sides and the top of the U-shaped iron core 701; as shown in fig. 6, during heating, the heavy rail steel 2 rail head is positioned in the induction coils 702 at the two sides and the top of the U-shaped iron core 701, and the heavy rail steel 2 rail head is heated.
As shown in fig. 7 and 8, two second electromagnetic induction heaters 11 are respectively disposed on both sides of the web of the heavy rail steel 2, and each second electromagnetic induction heater 11 includes a ferrite core 1101 and two induction coils 1102 disposed on the ferrite core 1101. During heating, the heavy rail steel 2 rail web is positioned between the two second electromagnetic induction heaters 11, and the heavy rail steel 2 rail web is heated.
As shown in fig. 9 and 10, the third electromagnetic induction heater 12 includes an E-shaped core 1201, and induction coils 1202 respectively provided in two recesses of the E-shaped core 1201. During heating, the bottom of the heavy rail steel 2 is positioned above the third electromagnetic induction heater 12, and the bottom of the heavy rail steel 2 is heated.
As shown in fig. 5, 8 and 10, a guide rail 703 and/or a fixing rod 704 are provided on the first electromagnetic induction heater 7, a guide rail 1103 and/or a fixing rod 1104 are provided on the second electromagnetic induction heater 11, a guide rail 1203 and/or a fixing rod 1204 are provided on the third electromagnetic induction heater 12, and the sliding grooves 101 are provided on both sides, the middle part and the bottom of the top of the apparatus body 10. The guide rail 703 on the first electromagnetic induction heater 7 is matched with the sliding grooves 101 on two sides of the top of the device body 10, and the first electromagnetic induction heater 7 is arranged on the top of the device body 10 through the guide rail 703 and/or the fixing rod 704; the guide rail 1103 of the second electromagnetic induction heater 11 is matched with the chute 101 at the middle part of the device body 10, and the second electromagnetic induction heater 11 is arranged at the middle part of the device body 10 through the guide rail 1103 and/or the fixing rod 1104; a guide rail 1203 on the third electromagnetic induction heater 12 is matched with the chute 101 at the bottom of the device body 10, and the third electromagnetic induction heater 12 is installed at the bottom of the device body 10 through the guide rail 1203 and/or the fixing rod 1204; both ends of all the fixing rods are mounted on the front end plate 102 and the back end plate by bolts 103.
The working principle of the electromagnetic induction heating device for the heavy rail steel is as follows: the control module 5 calculates the operation power of the corresponding electromagnetic induction heater according to the target temperatures of different parts of the heavy rail steel 2 and the real-time temperatures collected by the corresponding temperature sensors, and then controls the corresponding electromagnetic induction heater to operate at the operation power, so that the aim of heating the different parts of the heavy rail steel to the corresponding target temperatures is fulfilled.
The embodiment also provides a control method of the electromagnetic induction heating device for the heavy rail steel, which comprises the following steps:
step 1: acquiring initial power of the first electromagnetic induction heater 7, the second electromagnetic induction heater 11 and the third electromagnetic induction heater 12, and controlling the first electromagnetic induction heater 7, the second electromagnetic induction heater 11 and the third electromagnetic induction heater 12 to operate at the corresponding initial power respectively.
The method comprises the steps that before the operation power of the electromagnetic induction heater is adjusted according to the target temperature and the real-time temperature, the electromagnetic induction heater is enabled to operate at the initial power, when the operation power of the electromagnetic induction heater is adjusted according to the target temperature and the real-time temperature, the power of the electromagnetic induction heater only needs to be adjusted from the initial power to the operation power, compared with the situation that the operation power is adjusted from zero, the power adjusting time is greatly shortened, and the heating efficiency and the heating effect are improved.
Step 2: respectively acquiring the real-time temperature T acquired by the first temperature sensor 11The real-time temperature T acquired by the second temperature sensor 32And the real-time temperature T acquired by the third temperature sensor3I.e. obtaining the real-time temperature T of the heavy rail head before heating1Real-time temperature T of rail web2And the real-time temperature T of the rail foot3。
And step 3: according to real-time temperature T1And a target temperature T10Calculating the operating power P of the first electromagnetic induction heater 71According to the real-time temperature T2And a target temperature T20Calculating the operation power P of the second electromagnetic induction heater 112According to the real-time temperature T3And a target temperature T30Calculating the operation of the second electromagnetic induction heater 11Power P3The specific calculation formula is as follows:
wherein P is the operating power of the electromagnetic induction heater, T is the real-time temperature collected by the corresponding temperature sensor, and T is the temperature of the electromagnetic induction heater0Corresponding to the target temperature, C is the specific heat capacity of the heavy rail steel, and W is the mass per meter of the heavy rail steel in kg.m-1V is the running speed of the heavy rail steel during heating, eta is the efficiency of the electromagnetic induction heater, and the value is usually 0.6-0.7. In an exemplary manner, the first and second electrodes are,
P1is the operating power, T, of the first electromagnetic induction heater 71Real-time temperature, T, acquired for the first temperature sensor 101Is the target temperature, eta, of the heavy rail head1Is the efficiency of the first electromagnetic induction heater 7.
The operating power of the electromagnetic induction heater or the power required by heating the heavy rail steel is as follows:
wherein G is the heat treatment yield of the heavy rail steel in kg.s-1(ii) a The heating time of the heavy rail steel is
Wherein L is the length of the electromagnetic induction heater (i.e., the heating length); the advancing speed of the heavy rail steel is
At the same time
Wherein omega is the rotating speed of the motor 13, and r is the radius of the carrier roller; from this, equation (1) can be derived.
In this embodiment, different target temperatures T10、T20And T30According to the position (i.e. rail head, rail web and rail bottom) of heavy rail steelThe required heat treatment temperature.
And 4, step 4: and controlling the corresponding electromagnetic induction heater to operate with the operating power according to the difference value between the operating power and the initial power, so that the accurate control of the electromagnetic induction heater is realized, and the heat treatment temperature and the heat treatment effect of different parts of the heavy rail steel are ensured.
Specifically, according to the operation power P of the first electromagnetic induction heater 71And its initial power P10The difference between them controls the first electromagnetic induction heater 7 to operate the power P1To operate to heat the railhead to the target temperature T10The object of (a); according to the operating power P of the second electromagnetic induction heater 112And its initial power P20The difference therebetween controls the second electromagnetic induction heater 11 to operate the power P2To run to heat the rail web to the target temperature T20The object of (a); according to the operating power P of the third electromagnetic induction heater 123And its initial power P30The difference therebetween controls the third electromagnetic induction heater 12 to operate the power P3To operate to heat the rail bottom to the target temperature T20The purpose of (1).
In this embodiment, the initial power of the electromagnetic induction heater may be set to its rated power. To avoid the overload work of the electromagnetic induction heater and ensure the service life of the electromagnetic induction heater, when P is more than PForehead (forehead)When is in PForehead (forehead)Running; when P is less than or equal to PForehead (forehead)Then, run with P, wherein PForehead (forehead)Is the rated power of the corresponding electromagnetic induction heater.
When controlling electromagnetic induction heater power, still according to the heating demand control electromagnetic induction heater's of the different depth of hard coat in different positions mains current frequency, specifically do: determining the penetration depth of the heating current of the electromagnetic induction heater at the corresponding position according to the heating requirements of different hardening layer depths at different positions, and determining the corresponding power supply use frequency according to the penetration depth of the heating current, wherein the specific formula is as follows:
wherein, delta is the penetration depth of the heating current, m and rho are the resistivity of the heavy rail steel, omega, m and murThe relative permeability of heavy rail steel is shown, and f is the power supply use frequency. The electromagnetic induction heater has an eddy current effect, the eddy current effect enables current in metal to be mainly concentrated on the surface, the surface temperature is higher, the surface temperature is transmitted to the inside through heat conduction, the penetration depth of the current can be changed through the power supply use frequency control of the electromagnetic induction heater, and then the heating requirements of different hardening layer depths of different positions of heavy rail steel are met.
The present invention forms the distribution of magnetic lines of force 14 as shown in fig. 11 by changing the direction of the current in the electromagnetic induction heater. Compared with the prior art, the magnetic force line 14 formed when the device works has the following beneficial effects:
(1) compared with the prior art that the coil is integrally designed around the heavy rail steel (as shown in figures 12 and 13), the split design of the induction coil reduces the probability of the integral scrapping of the electromagnetic induction heater in an accident state;
(2) the iron core is arranged in the low-temperature area and has a local magnetic gathering effect, the magnetic line of force is designed in a short magnetic distance, the attenuation in the air is less, the heating efficiency is improved, and the energy consumption is saved;
(3) the magnetic force lines 14 are mainly concentrated on the heating part, and different electromagnetic induction heaters can independently control electrical parameters, so that the control of local heating of the heavy rail steel is realized, and the local heating requirement in the continuous heat treatment production process of the heavy rail steel is more suitable.
If a single electromagnetic induction heating device is used for heating, the heating device is required to operate at high power, so that the service life of the heating device is shortened, and the heating device is required to have a longer heating induction coil, which causes the heating device to be difficult to manufacture, high in cost and inconvenient to maintain, so that the embodiment also provides a heavy rail steel electromagnetic induction heating system which comprises a plurality of heavy rail steel electromagnetic induction heating devices; a plurality of heavy rail steel electromagnetic induction heating devices set up along the straight line interval, for example two adjacent heavy rail steel electromagnetic induction heating devices's interval distance is 1 meter. Heating different parts of the heavy rail steel to the Nth target temperature by the Nth heating device, entering the (N + 1) th heating device, continuously heating different parts of the heavy rail steel to the (N + 1) th target temperature, wherein the (N + 1) th target temperature is higher than the Nth target temperature, and repeating the steps in the same way, and heating the heavy rail steel to the final target temperature by the plurality of heating devices; the heating system composed of a plurality of heating devices is simple to manufacture, relatively low in cost, convenient to maintain and low in maintenance cost, when a certain electromagnetic induction heater is damaged, only the electromagnetic induction heater needs to be replaced, and the electromagnetic induction heater of the whole system does not need to be replaced.
The above disclosure is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of changes or modifications within the technical scope of the present invention, and shall be covered by the scope of the present invention.
Claims (10)
1. The utility model provides a heavy rail steel electromagnetic induction heating device which characterized in that includes:
a device body;
the first electromagnetic induction heater is arranged on the device body and used for heating the heavy rail head;
the second electromagnetic induction heater is arranged on the device body and used for heating the rail web of the heavy rail;
the third electromagnetic induction heater is arranged on the device body and used for heating the rail bottom of the heavy rail;
the first temperature sensor is used for monitoring the temperature of the heavy rail steel rail head;
the second temperature sensor is used for monitoring the temperature of the rail web of the heavy rail steel;
the third temperature sensor is used for monitoring the rail bottom temperature of the heavy rail;
the control module is respectively electrically connected with the first electromagnetic induction heater, the second electromagnetic induction heater, the third electromagnetic induction heater, the first temperature sensor, the second temperature sensor and the third temperature sensor;
and the power supply module is respectively and electrically connected with the first electromagnetic induction heater, the second electromagnetic induction heater, the third electromagnetic induction heater, the first temperature sensor, the second temperature sensor, the third temperature sensor and the control module.
2. The heavy rail steel electromagnetic induction heating device according to claim 1, wherein the first electromagnetic induction heater comprises a U-shaped iron core adapted to the shape of the heavy rail steel rail head, and induction coils respectively disposed on both sides and the top of the U-shaped iron core.
3. The heavy rail steel electromagnetic induction heating device according to claim 1, wherein two of said second electromagnetic induction heaters are respectively disposed on both sides of said heavy rail steel web, and each of said second electromagnetic induction heaters comprises an iron core and two induction coils disposed on said iron core.
4. The electromagnetic induction heating apparatus for heavy rail steel according to claim 1, wherein said third electromagnetic induction heater comprises an E-shaped iron core and induction coils respectively disposed in two recesses of said E-shaped iron core.
5. The electromagnetic induction heating device for the heavy rail steel according to any one of claims 1 to 4, wherein a chute is provided at a corresponding position of the device body, a guide rail adapted to the corresponding chute is provided on the first electromagnetic induction heater, a guide rail adapted to the corresponding chute is provided on the second electromagnetic induction heater, a guide rail adapted to the corresponding chute is provided on the third electromagnetic induction heater, and the first electromagnetic induction heater, the second electromagnetic induction heater, and the third electromagnetic induction heater are provided at corresponding positions of the device body through the respective guide rails and the corresponding chutes.
6. The electromagnetic induction heating device for the heavy rail steel as claimed in claim 5, wherein end plates are provided on both the front and back surfaces of the device body, and a closed cavity is formed by the device body and the end plates; an inlet or an outlet matched with the shape of the heavy rail steel is formed in the end plate; the first electromagnetic induction heater, the second electromagnetic induction heater and the third electromagnetic induction heater are all provided with a fixed rod, one end of the fixed rod is fixed on the end plate on the front side, and the other end of the fixed rod is fixed on the end plate on the back side; wherein the front surface of the device body refers to the surface of the heavy rail steel entering the device during heating.
7. A control method of the heavy rail steel electromagnetic induction heating device according to any one of claims 1 to 6, characterized by comprising:
respectively acquiring real-time temperature T acquired by a first temperature sensor1The real-time temperature T acquired by the second temperature sensor2And the real-time temperature T acquired by the third temperature sensor3；
According to the real-time temperature T1And a target temperature T10Calculating the operating power P of the first electromagnetic induction heater1According to said real-time temperature T2And a target temperature T20Calculating the operating power P of the second electromagnetic induction heater2According to said real-time temperature T3And a target temperature T30Calculating the operating power P of the second electromagnetic induction heater3；
Controlling the first electromagnetic induction heater to have power P1Operation, controlling the second electromagnetic induction heater to have power P2Operation of the third electromagnetic induction heater with power P3And (4) operating.
8. The control method according to claim 7, wherein the operating power is calculated by the formula:
wherein P is the operating power of the electromagnetic induction heater, T is the real-time temperature collected by the corresponding temperature sensor, and T is the temperature of the electromagnetic induction heater0To correspond to the eyeThe standard temperature, C is the specific heat capacity of the heavy rail steel, and W is the mass per meter of the heavy rail steel in kg.m-1V is the running speed of the heavy rail steel during heating, and eta is the efficiency of the electromagnetic induction heater.
9. The control method according to claim 7 or 8, characterized in that the power of the first electromagnetic induction heater, the second electromagnetic induction heater and the third electromagnetic induction heater is controlled, and meanwhile, the power supply current frequency of the corresponding electromagnetic induction heater is controlled according to the heating requirements of different hardening layer depths at different positions of the heavy rail steel.
10. An electromagnetic induction heating system for heavy rail steel, characterized by comprising a plurality of electromagnetic induction heating devices for heavy rail steel according to any one of claims 1 to 6; and the multiple heavy rail steel electromagnetic induction heating devices are arranged at intervals along a straight line.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114986849A (en) * | 2022-06-02 | 2022-09-02 | 昆山捷嵘发测控设备有限公司 | Cable high-frequency preheater and preheating method |
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| CN114986849A (en) * | 2022-06-02 | 2022-09-02 | 昆山捷嵘发测控设备有限公司 | Cable high-frequency preheater and preheating method |
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