Induction heating power supply is widely used in metal heat treatment, quenching, annealing, diathermy, melting, welding, hot sleeve, semiconductor material refining, plastic heat sealing, baking and purification; using induced current generated under high frequency magnetic field The conductor itself heats up and heats up. Compared with furnace heating, combustion heating or electric heating wire heating, induction heating has the advantages of remarkable energy saving, non-contact, high speed, simple process and easy automation.
The induction heating power supply is mainly composed of a rectifying unit, an inverter unit, a resonance output unit, and a sensor. The rectifying unit converts the power frequency three-phase AC voltage into a DC voltage; the inverter unit converts the electric energy into high frequency electric energy of several thousand to hundreds of kilohertz; the resonant output unit is connected to the inverter at one end and connected to the inductor at the other end, and is isolated and Impedance matching, which produces a powerful high-frequency current in the inductor through resonance. When heated, the inductor induces a high frequency current in the workpiece, so the conductor is quickly heated. In the early induction heating equipment, the high-frequency inverter device required by the inverter unit determined the form of the device, and it experienced the development process from the electron tube and the thyristor to the current widespread adoption of the IGBT.
In the current mainstream IGBT induction heating products, there are still many differences in circuit and structure. From the rectifier unit, there are controllable rectification mode and uncontrollable rectification mode; from the inverter unit, there are pulse width modulation inverter mode and chopper voltage regulation inverter mode; from the resonance output unit, there are parallel resonance mode and series resonance mode. Various circuits and structures vary in efficiency, power factor, reliability, and the like.
Analysis of new technology of induction heating power supplySeries and parallel
Induction heating power inverters mainly have parallel inverters and series inverters. The output of the series inverter can be equivalent to a low-impedance voltage source. When the two voltage sources are connected in parallel, the amplitude, phase and frequency of each other. Different or fluctuating will lead to a large circulation, so that the current of the inverter device is seriously uneven. Therefore, the parallel inverter has difficulty in parallel expansion; and for the parallel inverter, the DC large reactor at the input of the inverter It can act as a current buffer between each parallel inverter, so that the AG/DG or DG/DG link at the input has enough time to correct the deviation of DC current, achieve multi-machine parallel expansion, transistorized super audio, high frequency current Parallel inverter structures are often used, and parallel inverters are easy to be modularized and large-capacity is one of the main reasons.
The load of the induction heating power supply is various, and the power inverter and the load are an organic whole. The matching transformer is used to connect the power supply and the load sensor. The matching transformer for the high frequency and super audio power supply is from the magnetic material to the winding. The structure is being further optimized and improved. At the same time, three passive components can be replaced by three passive components from the circuit topology to eliminate the transformer and achieve efficient and low-cost matching.
Induction heating power supplies, thyristors, transistors and tube tubes can be produced in China. Thyristor power supplies have been in production for many years. IGBT power supplies are more user-friendly because of their advantages. The IGBT power supply has high electrical efficiency and low voltage, but the price is high, and it is gradually replacing the high-frequency power supply of the tube. Portable small-scale high-frequency power supplies are widely used in China because of their low price and convenience, and even enter foreign markets.
Annealing and tempering applications
Annealing heats the workpiece to the appropriate temperature, uses different holding times depending on the material and workpiece size, and then slowly cools (slowest cooling rate) in order to achieve or close the equilibrium of the metal internal organization for good process performance and performance. Or prepare for further quenching.
There are several advantages to using induction heating instead of gas or furnace for preheating. Thermal conduction can be carried out directly, which will minimize heat loss and energy loss, increase production efficiency and improve product quality.
At the same time, the heat can be precisely controlled, which can reduce the temperature during welding and thus reduce the cooling rate. In addition, it also helps to reduce the risk of cold cracking and hardening. With induction heating, you don't have to face the hot gas, which improves the working environment, reduces the need for heat dissipation system, and reduces the risk of fire.
Analysis of new technology of induction heating power supplyInduction heating power supply is a low-energy, high-efficiency metal material heating power module, which has been widely used in more than 40 countries around the world. This paper will introduce the working principle of traditional inductive power supply through the analysis of the circuit structure of the inductive power supply, so that engineers can carry out professional technical innovation on the basis of research on its working principle.
Under normal circumstances, the traditional induction heating power supply in the main circuit structure, mainly consists of the following four parts: uncontrolled rectification, large capacitor energy storage filter, inverter circuit and resonant load.
In the process of working, the heating power source converts the alternating current into direct current through uncontrollable rectification, and then converts the relatively stable direct current into the power supply of the inverter circuit through large-capacitance filtering, and realizes the inverse of the system on the inverter side in the later stage. Variable output and power regulation. The following figure shows the structure of the traditional model of induction heating power supply circuit.
From the figure we can see that the heating system of the entire power supply has DSP digital chip for control. The voltage and current detecting device detects the voltage value and current value of the DC bus, and then sends the value to the DSP processing chip to quickly realize power feedback. The entire load detection process includes temperature detection and frequency tracking, and synchronous feedback is achieved by transmitting the temperature value detected by the infrared sensor to the DSP. The processor can then feed back to the DSP by detecting the resonant current and voltage signals of the load to achieve frequency tracking.
When the DSP chip receives the corresponding current and voltage signal, it will internally perform A/D conversion and hold on the feedback signals such as voltage and current, and compare the actual output power with the digital given power through digital multiplication. The deviation is digital PID control. Through this digital control method, the induction heating power supply can realize the closed-loop control of the power output power and the DPLL frequency tracking. The fault detection protection circuit monitors the faults such as water shortage, over-temperature over-voltage and over-current, and is compared by the DSP fault processing subroutine. After the judgment, all kinds of faults are handled in the interrupt mode, and the alarm is displayed.
However, since the traditional induction heating power supply adopts the large-capacitance passive filtering mode of most models, it is easy to cause input current distortion and cause harmonic pollution to the power grid system, thus causing the input power factor to be lowered. At the same time, this method is also not conducive to saving electricity costs. Therefore, a new heating power module with DSP parameter correction function has begun to appear on the market.
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