工業電熱製品 総合ガイド Comprehensive Guide to
Contents
1. g m EE IGBT LL TIT EL LIL HH HILLHT ELLLLLNLLLLLLL r m E 5 Transistor inverter a HF IGBT _ LI I LIIII 11 HF IGBT inverter J E lhyristor inverter LL hh Lh WGBT 1 T ms Es i E E ENEED GG 0 kHz Frequency kHz Thyristor inverter 60 13 000KkW 50Hz 10kHz FH Standard specification Power 60 to 13 000kW Frequency 50Hz to 10kHz Application Induction furnace Billet heater Various heating systems f ail rm 11 Our semiconductor type power supplies cover the industry s widest frequency band ranging from commercial frequency to figures in the order of MHz thus satisfying various melting heating loads In addition our substantial protective devices ensure safety when faced with unanticipated circumstances Transistor2. 50 60HZ Operating principle of induction heating AN Operating principle Inserting and removing a bar magnet from a spiral conductor changes the magnetic field causing a current to flow through the conductor This is referred to as electromagnetic induction By using this phenomenon and by applying an alternating current to a coil instead of inserting and removing a magnet in order to produce an alternating magnetic flux an eddy current is produced in an object to be heated The heating by Joule heat attributable to this eddy current loss is called induction heating In this case the eddy current is induced in that part of the object which is adjacent to the coil and the current intensity is highest on the surface layer and decreases to
3. 9 Electricity expense reduced by approximately 3096 9 Reduced maintenance cost no need to replace vacuum tubes 9 Eliminated anxiety about vacuum tube supply Example of updating Electric resistance tube welding power supply C FSS vr 1 IHSS Boiler Superheated steam generator One through generation of superheated steam from tap water TETO TEIDE C3 LIAHNE e 9596 e 450C e 9 Operable by anyone without a license 9 Energy saving achieved by heat efficiency as high as 95 9 Generation of superheated steam at 450 C 9 Improved environment achieved by entirely electrical operations Ln It T 4i gd Em f ama ERN W id W m mn m md amm m Em Dam mam um m Ta OE Un L nm Y j AITE m qu 72 I S 7 7 5 V F uq i J5 v B i s Y wm 1 19624 G000 Delivery record exceeding 2000 units and record breaking items since 1964 T Low f ibl i ion f l
4. IRAE veg wm Heating in general Drying Liquid heating Shrink fitting Roll heating Internal heating Bore heater Jacket heater High frequency baking Plane heating Heating oven Jacket plate heater Electromagnetic cooker 20 17 m Y d N fre 254 B 1 NEN Principle a of Induction Heating Reference data 9 Current penetration depth 0 368 0 6 5 03 p uf cm EE O O em 20 1 000C 158 3 450C 8 U Hos 1 20 1 000 f HZ
5. cm a Cm 8 gt 2 55 fc fc 1288p ua Hz 9 How to select the frequency In induction heating the selection of frequency is very important as it considerably affects the heating efficiency and running cost To allow the energy to be efficiently absorbed by an object to be heated a higher frequency is required for a smaller object or a comparatively low frequency for a larger object For surface hardening the object must be cooled immediately after raising the frequency to decrease current penetration depth 6 and then shortening the heating time to concentrate the heating part on the surface layer Generally the surface power density is 1 to 5 kW cm However if the whole object is to be heated the frequency must be lowered to make 6 1 3 to 1 7 of the diameter of the object and the Frequency selection 100kHz 10kHz kHz Frequency kHz heating time must be comparatively long a power density of 0 01 to 1kW cm is oft
6. LCA G008 3 Annual pouring volume 4480t year Example of estimation the case in which alternate melting with two 2t cupolas was replaced by simultaneous melting with two 11 600 kW high frequency furnaces Source Environmental economical effect of the introduction of induction furnaces and development of the life cycle assessment LCA method Graduate School of the University of Tsukuba Faculty of Systems and Information Engineering Department of Risk Engineering March 2008 Change of heat source for heating Combustion furnace Inline induction furnace 20 30 e 1 3 e O9 20 to 30 increase in production capacity 9 Heat treatment cost reduced to 1 3 9 Reduced thermal strain achieved by short term local heating 9 Space saving Example of change Solution treatment of stainless steel gt Updating of a high frequency power supply system Vacuum tubes Semiconductors e 3096
7. High energy conversion efficiency Approximately 8596 of input power is used to generate plasma The power control on the high frequency side ensures stable operation and a high speed response to sudden load changes before and after plasma generation e 450C 15 e Superheated steam of 450 C can be generated directly from tap water within 15 minutes Easily installed and operated by anyone for sterilization recycling degreasing and carbonization purposes in food processing We have been and will keep developing products integrating advanced technologies providing them for various fields We are happy to receive your feedback with your concerns and updating of your production process e 8096 e e Im sS Achieves efficiency as high as 809 e Fluids in various states including creamy liquid and water can be heated rapidly and controlled a
8. iiic Fuji Electric Thermo Systems Co Ltd fulfills your expectations concerning the solving of environmental problems and enhancing energy saving JQA 2034 ca erttication optaine A Printed on recycled paper Fuji Electric Systems Co Ltd Fuji Electric Thermosystems Co Ltd Gate City Ohsaki East Tower 11 2 5520 Minamitamagaki cho Suzuka Mie 513 8633 Japan Osaki 1 chome Shinagawa ku Tokyo 141 0032 Japan Phone 059 383 8833 Phone 03 5435 7114 Internet address http www fesys co jp Internet address http www fuji thermo co jp Information in this cata
9. We look forward to hearing fror 16 PDCA Creation of a long term maintenance plan ideal for the status of your facilities After sale service system e e e e Implementation of preve maint areas to be improved of the plan according ults of inspection and ction facility 17 After sale Service System To ensure your equipment can be used safely smoothly and with peace of mind it is esse
10. Hot strip mill Soaking furnace Acid pickling line e iin dge heater C dge temperature increase Steel Making Technology Temperature compensation and heating control based on our induction heating technology in the smelting and product manufacturing processes not only improve quality save energy and increase yield but also contribute to the development of new products The Fuji Electric group has been focusing on combining the products manufactured by induction heating with drive measurement and control technologies Large bore pipe hardening system Hardening tempering Annealing hardening tempering Thick steel plate Plate heater Thin steel plate heating system Thin steel plate Tinned steel plate Galvanized steel plate Alloying furnace ese BM Coated steel plate baking line eDrying baking 732 il Ax Colored steel plate 10 MHz No 1
11. Condition ERT S 9 Current penetration 8 The eddy current is intense on the surface layer of the object to be heated and attenuates exponentially toward the inside This is called the skin effect The depth from the surface at which the eddy current density is 0 368 times that on the surface is referred to as current penetration depth and is important when using induction heating Current penetration depth 6 is expressed by the following formula The lower table gives examples of penetration depth 6 for different materials calculated by the formula 675 03 p uf cm where p Specific resistance of metal U cm For steel 20 at normal temperature and 128 at 1 000 C For copper 3 at normal temperature and 8 at 450 C u Relative permeability 1 for nonmagnetic material In case of a magnetic material it changes with the magnetic field intensity For steel it is between 20 and 1 000 in heating f Frequency Hz Current penetration depth of different materials cm Frequency Hz 50 500 20000 21C 0 64 0 14 0 0025 Carbon steel Magnetic zone 300 C 0 86 0 19 0 0035 300 C 1 30 0 29 0 0054 800 C 7 46 2 37 1 67 0012 Non magnetic 1250 C 7 98 2 53 1 879 0 13 ur Melting 9 00 2 85 2 01 0 14 1550C fi 850 C 1 95 0 62 0 44 0 25 0 14 0 03 Copper Melting 1550C 3 30 1
12. ottama A Higher quality added values Highly accurate temperature control Ultra high temperature heating Li Ii Z JA22 E El gt Change of heat source for melting Cupola Induction furnace e Reduced running costs e 9 Higher quality fal 9 Improved environment e COs Reduced CO emissions 6 Ease of finding successors Unit price of coke and break even point example Overall cost for induction furnace Overall cost for cupola Unit Xmillion 400 300 200 100 0 D 10 20 30 40 5060 807490 100 100 200 300 400 500 kg Unit price of coke Y kg CO 12 Example of percentage of CO2 emissions for 12 years 189 Cupola 18 159 Cupola 15 129 Cupola 12 Induction RUSSE 300 976 4480t 6 1 x gt 1 600kWx em 1896 Coke ratio 1896 em 1 4 Alt 15 Coke ratio 1596 em 1 7 Alt 12906 Coke ratio 1296
13. furnace Pouring Of turnings Spiral stirrer e The structure without a contact area with molten metal facilitates maintenance The rate of solution of materials can be increased to enhance furnace productivity SM S Spiral stirrer SMS e e Waste aluminum materials and various types of lightweight scrap are taken into molten metal efficiently without making physical contact which achieves high yield By applying this technology to the agitation of molten metal prior to forging the crystal structure can be refined Forcible agitation is performed using electromagnetic force generated in molten metal to mix in materials and achieve the homogenization of components and temperature thus improving the yield saving energy and enhancing characteristics based on refinement of the crystal structure PI
14. Consideration for the surrounding environment W Zero emissions of exhaust gas or dust from combustion Space saving W Eliminating the need for incidental devices such as boilers and fuel tanks Possibility of energy resource saving Reduced heat loss achieved by direct local heating 9 Improved productivity and power saving Rapid heating Line automation Inline heating achieved by lectric heating Safe operation Free from the danger of flames No need for combustible fuels Comprehensive cost reduction Fewer workers Reduced maintenance cost W Shorter startup time C C Improvement of the Industrial environment Minimized heat dissipation from devices W Reduced waste _
15. Energy saving Standard specification Power 60 300kW e Accurate temperature analysis performed in a short time e Facilitated automation Space saving Standard specification Furnace capacity 150 60 000kg ES Power eges OHIO TO Large scale casting Continuous operation Component adjustment 1 Induction furnace with refining function Dice heater Low frequency crucible type induction furnace _Pressure type automatic pouring furt lace Induction heating a master card for energy saving in metal heating is applied to various metal heating and thermal processes using billet heaters special billet heaters and mold heaters to support innovative production processes Creating optimal quality in a comfortable environment is the hallmark of induc tion heating Billet heater for warm forgin Standard specification Power 180 1 300kW e 3 The heater for warm forging integrates the following three fu
16. 50kHz o R BAN MOSFET MOSFET inverter EO TD NR SA 1 OOkKW 1 000kW 50kHz 500kHz HR BERAR Standard specification Power 20 to 75kW Unit type 100 to 1 000kW Frequency 50 to 500kHz Ap tion B MHz MHz class i IOOKW 3OOKW bOOkHz 1 MHz OHR m u JE Ia 88 CB cime ec Hx O AC Uc Sane BHSE U 1 f A AN High melting point alloy smelting forging FESTER T OD REC EDU ICT Melting technology capitalizing on levitation melting has been integrated with precision forging 278 FH F8 Power supply for depositi Ultra high frequency furnace kHz Direct i
17. jn L4 43H 401 U 000kW II 0 ype HUI 40T10 000kW for cast iron L FIARE I FE J EERE 60T 3 500kW 60T 3 500kW for copper alloy 85T 13 000kW a A a a ala r T 85 T 60T 2 000kW Low frequency channel type induction furnace LE MM E e focus not only on improving the operability safety and maintainability o CO gt our products handling molten metal but also on improving the environment through saving energy and reducing CO emissions High frequency crucible type induction furnace JIUZt Lr LL Vacuum induction furnace Aluminum billet heater Standard specification Standard specification Standard specification Furnace capacity 30 25 000kg Furnace capacity 7 000 50 000kg
18. and Heating Test Fuji Electric Thermo Systems Co Ltd is ready to perform various test melting and heating tests Contact us with any requests or if there is something you would like to do C e 500cc 100kg e IHSS Examples of test facilities 6 500cc levitation melting furnace 9 High frequency 100kg melting furnace 9 IHSS test system 9 High frequency power supply s e M Solution engineering Your requests and concerns Proposal of solutions and discussion on sample processing test Preparation for test Preparation and provision of sample materials Implementation of sample processing test Your witnessing IS welcome Specific proposals for introducing facilities
19. 04 0 74 0 43 0 23 0 05 Afni 6596 850C 2 52 0 79 0 56 0 33 0 18 0 04 Brass copper Melting 1550C 4 57 1 44 1 02 0 59 QE 0 07 850 C 2 01 0 64 0 45 0 23 0 14 0 03 Aluminum Melting 750C 3 70 T7 0 83 0 48 0 26 0 06 21 Reference data 1 5kW cm C Oo 1 3 1 7 0 01 1kW cm
20. Fo e Front runners IREA m Comprehensive Guide to Industrial Melting and Heating E hi a 3 i k E E em UNE j d NC 30m Advantages of Electric Heating Electric heating with wide ranging applications ensures improved productivity environmental preservation and enhanced safety thus facilitating innovative production Its high heating rate and superior controllability improve productivity in various heating processes Direct material heating and local heating of the necessary areas only minimize energy consumption Electric heating which does not involve combustion helps improve the environment and safety
21. Fumace capacity 10 20 000kg FB Power COT 000kW FB Power T OO TOCO E5 Power 1 800kW Degassing of molten metal High power rapid melting Retaining and temperature increase of molten metal Refining e Improved productivity e e CO Reduction in CO2 emissions Cushioning between melting furnace and casting line Production of high quality steel e Recycling of waste molten metal Standard specification Power 300 1 000kW e CAREEN EE Fully automatic optimum operation control system One touch coil replacement system Energy saving Standard specification Standard specification FES Funace capacly 2 500 8 500kg Furnace capacity 2 000 8 000kg 87 Power EO OONN Es Power 1 800 4 000KW N 4 N e Automatic pouring into mold e iioc SISSE pisi e Melting and dezincing of zinc plated steel scrap 2 727 y ST Pouring while receiving molten metal also allowed MEIRA Removal of impurities e Environmental improvement Applicable to molding lines
22. SARA AAE RTR Electromagnetic agitator for molten aluminum ret I I 1 C e Thisis a hybrid molten aluminum retention furnace integrating an electromagnetic agitator directly into the excited crucible The temperature of molten aluminum can be controlled to within 1 C Molten aluminum can be agitated in a vertical direction Electrode Crucible PA1000 Molten aluminum Coil for agitation Himan BIZ SAREE e Plate mill Tundish heater E e Molten metal temperature increase X TTT e Higher quality achieved by the molten metal refining effect e Slab heater e Slab RN increase u P
23. ation in pipe manufacturing Such innovation includes significantly reduced running EA VAN X ENSE E costs and space saving in electric resistance tube welding and surface processing Our pipe making technology improves the manufacturing of various pipes including steel and nonferrous pipes f Electric SEM tube welding equipment Ji SEURE S Heater for surface processing drying Contact type Heater for surface processing drying n Seam f Electric resistance tube welding CA ES 2 Heater for reducer Heater for thermal treatment p A for T treatment 4 Heater for reducer m Aal EEI OBRT d ORARI EIT Molten aluminum electromagnetic agitator y Reverberatory
24. en used When heating an entire metal bar the frequency should be selected so that the relationship between current penetration depth 6 cm and metal bar radius a cm is a 8 72 25 This frequency is referred to as minimum allowable frequency fc and is expressed by fc 128p ua lt Hz The following figure is an example of setting the frequency for heating a steel material by a billet heater 1 200C When heating steel to 1 200 C red line denotes optimum outer diameter 1kHz 20 40 80 100 120 mm Material outer diameter 22 B3BA C EQRE Creation of 3S C E Concept of Manufacturing of Fuji Electric Thermo Systems Co Ltd lA 1st S Ensuring Safety Provision of products ensuring safety 1 2nd ieving S GA 3rd S Pursuit of Stability Provision of facilities that can be operated stably MEN LLLA Ln 5e 100 1 y efficient products ystems with minimum CO2 e Measures to prot
25. log is subject to change without notice 2009 10 H2009m E 1980 KD CTP5M Printed in Japan
26. nace T B l 11 F RBOME BH EE LG ER REEL ELE E pim HEEL mo mm i rr WW unns rout Eom iilii E Facility improvement update proposal Sale of various parts such as spare parts and consumables 18 b Ee unui b mu Principle of Induction Heating L
27. nctions Preheating dipping and heating e Enhanced maintainability achieved by a simplified dipping device Standard specification Power 50 200kW e Local heating of the internal surface of circular work Bore heater Note See the brochure of each system for details Heater for mold heatinc Standard specification Power 50 200kW e Heating up to the specified temperature in a short time Accurate temperature control Space saving and improved work environment Standard specification Power 20 170kW e Heating of ceramics in inactivated gas Uniform heating e 2000C Ultra high temperature heating up to 2 000 C or higher Heating device for ceramics Advancement of high frequency power supply technology spawns innov
28. nduction heating is performed using an ultra high frequency of several hundred kHz to melt glass and concrete _Power supply for plasma generator 8 el High melting point metal melting unit F3 EDANDA PCs Levitation melting technology using a water cooled crucible facilitates the production of alloys with high melting points purities and specific gravity differences MESE E E EA e MG 2096 e o nus Higher efficiency and energy saving by approximately 2096 higher than MG achieved by the semiconductor system Easy maintenance and inspection lower maintenance cost Adoption of automatic graphic panel improves operability and ensures higher efficiency 14 e 8596 e AX SETE BI Ge CO SUUS E FEE BLU
29. ntial to prevent potential trouble and constantly maintain the equipment in optimum condition Once trouble occurs not only are time and cost required for restoration but sudden equipment suspension may also result in significant losses to your business partners To prevent the occurrence of such trouble we recommend that you perform plan do check act PDCA activities for maintenance thus achieving optimum equipment maintenance status Major after sale service menu for industrial electric heating Repair and replacement of furnace coil insulator Repair of furnace body Overhaul of inductor O m mu wuraru FE rErira rFesrarmmrwrea rmresrmrera m Diagnosis of relining timing of retaining pouring furnace Periodic facility inspection service a iia FE i km w EX Spare coil new manufacture of spare furnace and spare inductor Various on site repair services Coil replacement Cement repair Relining work of channeltype fur
30. t a constant temperature Saves more energy than heating using fossil fuels steam When the coil is removed When heating is performed e e e 1 200C The detachable coil can be attached to the objects to facilitate heating The lightweight portable coil can be used for heating immediately regardless of location e Since the coil is protected with the refractory heating of up to 1 200 C is possible 15 Dispersion t e e Can be placed in the desired venue when necessary to create a heating system for producing the required quantity e Individual power supply control generates optimum heating patterns The self cooled power supply is easily installable VARF e IZENA Test Melting
31. vener 00 0 0 NN O FB Bb 3G30kW 1 7kHz FH on IGBT IGBT inverter for melting mAECEER F EDS T T Fuji MELT PLUS Hir supply control 750 6 000KW 3 tm i 50 500Hz mer o No 2 ESP ower for HR furnace No 2 sos SAM _ 10096 Power allocation Standard specification Power 750 to 6 000kW Frequency 50 to 500Hz Application Induction furnace simultaneous multiple furnace operation Billet heater i GBT IGBT inverter unit compact type e Os EE ere E 10 30kHz Hi Standard specification Power 20 to 50kW Frequency 10 to 30kHz Application Compact melting system semiconductors glass etc for film deposition 10096 M Adjusting system No 1 Power for furnace No 1 j ja m X 50kW 50kW unit B OkW 20kW unit 12 HFIGBT4ZJC 4 HF IGBT inverter O 250 2000kW 100 800kW 5 30kHz S30
32. ward the inside The energy can be concentrated on the part of the object to be heated for efficient and quick heating thereby improving the productivity and workability Induction heating is used for metal melting furnaces as well as for induction heating equipment for raising the temperature of an object to a desired level while controlling it According to the frequency used there is the low frequency furnace commercial frequency 50 60Hz and the highfrequency furnace the selection of which depends on the application Besides the frequency changing the magnetic field intensity can vary the charged energy quantity and hence the heating rate Thus induction heating enables the heating conditions to be flexibly changed to suit particular requirements Alternating magnetic flux Penetration depth Power supply Eddy current Heating coil Object to be heated Applications Casting Melting Holding iban ER Forging Forging Roll forming Extrusion Drying KEEL Heat treatment Quenching Tempering Annealing Bonding Welding Brazing Soldering scm
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