Horizontal Steel Induction Billet Forging System

All Solid-State IGBT Drive Circuit

ROCHO INDUCTION steel billet forging system adopts all solid-state IGBT frequency conversion control technology, IGBT drive circuit provide the quick heating speed to reduce oxidation and deformation of the steel billet, to provide more stable and better heating uniformity.

The Principle Of Induction Forging

The steel billet induction forging system adopts the principle of medium-frequency electromagnetic induction heating. After the induction coil is energized, a magnetic field is generated, and magnetic lines of force cut metal bars such as steel bars, copper bars, iron bars, aluminum bars, etc., thus generating induced current, namely, eddy current, inside the bars.

The heat of induction heating generates induction current inside the bar, so the metal material is heated evenly and the temperature difference between the core and the surface is extremely small. The induced current enables the metal bar to be rapidly and evenly heated by reaching the required temperature in a very short heating time; so the surface of the heated bar is less oxidized with less workpiece deformation.

The Structure Of Steel Billet Forging System

The complete set of steel billet induction heating forging system consists of 12-pulse medium frequency induction heating power supply, medium frequency compensation capacitor, steel billet forging furnace, induction coil, PLC electrical control system, automatic feeding system, infrared thermometer and other main parts.

Induction Heating Power Supply
The steel billet induction heating forging system adopt medium frequency induction heating power supply, which has multiple protection functions including over-current protection, water shortage protection, over-heat protection, over-voltage protection, short-circuit protection, phase failure/loss protection and other alarm functions. It will automatically alarm in case of faults, greatly improving the reliability of the equipment.

PLC Automatic Control System
The steel billet induction forging furnace can be equipped with a PLC automatic control system to realize automatic feeding, automatic blanking, automatic completion of heating process, reducing labor costs, and high production efficiency.

Temperature Control System
The steel billet induction forging furnace is equipped with an infrared thermometer, which can set the heating temperature and accurately control the heating temperature through the PLC control system. When reaching the required temperature, the bar material will automatically convey to the next process for forging. The application of temperature control system can realize accurate control of temperature and improve product quality and qualified rate.

High Quality Forging Furnace
The induction coil inside of the steel billet induction furnace uses T2 copper tube with oxygen-free copper windings, and the furnace wall thickness is greater than 2.5 mm. The furnace lining is made of high-strength aluminum alloy, which can reduce magnetic flux leakage and increase the service life of billet induction heating equipment.

Save Material Cost

Compared with the traditional heating methods such as oil heating and coal heating, induction heating possesses fast heating speed, can continuously carry out forging tasks, does not waste heating blanks caused by power or equipment failure, and saves the cost of materials and forging dies, each ton of billet can save at least 20-50KG of steel raw materials.

Applications:

ROCHO INDUCTION specializes in the production of steel billet heating furnaces, steel rod continuous heating furnaces, and steel bar online heating forging equipment. We can offer customers with customized heating processes, and turnkey solution, including:
complete engineering design,
equipment manufacturing,
installation and commissioning,
operation training and maintenance.

Technical Specification

Power	Frequency	Transformer Capacity	Secondary Voltage	Rectifier Pulse	Induction Coil Voltage	Power Consumption	Steel billet size	Heating Time	Heating Temperature
800kW	500-8000Hz	630kVA	3*380V	6Pulse	800V	450kW·h/t	60601200mm	30second	≤1250℃
1000kW	500-1000 Hz	1250kVA	660-380V	6Pulse	1200V	380kW·h/t	60601500mm 60601300mm	38second 38second	≤1250℃
1500kW	500-1000 Hz	1600kVA	660-380V	12Pulse	1200V	370kW·h/t	70703000mm 60603000mm	85second 65 second	≤1250℃
2000Kw	500-1000 Hz	2200kVA	660-380V	12Pulse	1200V	360kW·h/t	80803000mm 70703000mm	80second 60second	≤1250℃
3000kW	400-1500 Hz	3500kVA	950V	12Pulse	2800V	350kW·h/t	1001006000mm 80806000mm	165second 110second	≤1250℃
5000kW	80-1500 Hz	6000kVA	1250V	12Pulse	2800V	340kW·h/t	1301306000mmm 1201206000mm	115second 110second	≤1250℃
8000kW	80-1500 Hz	10000kVA	1250V	24Pulse	2800V	320kW·h/t	150150600mm 1301306000mmm	110second 80second	≤1250℃
10000kW	70-1500 Hz	12500kVA	1500V	24Pulse	2800V	300kW·h/t	2002006000mm 150150600mm	145second 80second	≤1250℃

ROCHO technical team can customize the induction heating power supply for special purposes according to customer requirements, and design capacitors, frequencies and induction coils according to the metal workpiece to be heated and heating requirements to achieve the best heating effect.
When you need to consult or order machine, please provide the following information:
(1) the local industrial voltage;
(2) the name and material of the product to be processed;
(3) the required process: heating, brazing, hardening, melting or annealing;
(4) the size of the product to be processed, such as diameter and length and if drawings can be provided.

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