Induction heating type heat treatment equipment uses electromagnetic induction to generate eddy current heating phenomenon, and heats the surface of the workpiece for heat treatment. Due to its high production efficiency, low energy consumption and easy to achieve automated production, less pollution and safety, the application is increasingly widespread. According to the frequency of the alternating electromagnetic field generated by the equipment, it can be divided into three categories: high frequency, medium frequency and power frequency (high frequency frequency is 30~500KHz; intermediate frequency is 1~10 KHz; industrial frequency is 50Hz industrial alternating current) . Induction heating equipment uses a power supply voltage of 220 to 380V, but some devices have internal voltages of up to 10kV. Therefore, when using induction heating heat treatment equipment, attention must be paid to the safety of high-voltage electricity and the pollution of electromagnetic radiation.
1. Safe operation of high frequency induction heating equipment
The high-frequency induction heating equipment is mainly an electronic (vacuum) tube, which generates high-frequency electromagnetic oscillation. The electric power is 10~200kW, and the highest voltage in the machine is about 15kV. Therefore, it is required that the insulation performance inside the equipment must be good, and the relevant parts such as the casing must be reliably grounded. An insulating rubber mat should be placed at the operating station. Protective wooden railings should be placed next to the equipment, painted with red and white paint. Hang high voltage electric danger sign. The light should be bright and well ventilated at high frequencies, and the indoor temperature should be controlled at 15~35 °C. An air exhaust device is installed to eliminate the soot exhaust gas emitted when the workpiece is heated. Since the frequency of the high frequency device is 30 to 500 KHz, RF radiation is generated. When the body absorbs a certain amount of radiation, biological changes occur. The biological changes increase with the decrease of wavelength (increased frequency) and manifest as neurasthenia syndrome and autonomic nervous system dysfunction. Therefore, shielding measures should be taken for the radiation field sources of the equipment (such as high-frequency transformers, feeders, working capacitors, coupling capacitors and inductors). In order to prevent electromagnetic wave leakage and affect electronic equipment and radio communication in the vicinity (about 100m), the whole room should be shielded, and the radiation intensity of the working environment should be within the specified range (electric field strength E≤20V/m; magnetic field strength H) ≤5A/m. Pay attention to the operation:
(1) There must be two people above to operate the high frequency equipment and specify the person in charge of the operation. Wear insulated shoes, insulated gloves and other protective equipment.
(2) The operator must be familiar with the operating procedures of the high-frequency equipment. Before starting the machine, check whether the cooling system of the equipment is normal, and then send power after normal, and operate according to the operating procedures.
(3) All the doors should be closed before work. The door should be equipped with electrical interlocking device to ensure that the door cannot be powered before it is closed. After the high pressure is closed, it is not allowed to move to the rear of the machine. It is strictly forbidden to open the door.
(4) The workpiece should be free of burrs, iron filings and oil stains, otherwise it will easily arc with the sensor when heated. Arcing now produces arcing that can both damage vision and damage sensors and damage equipment.
(5) High-frequency equipment should be kept clean, dry and free of dust. If abnormal phenomena are found during work, the high-voltage power should be cut off first, and then the fault should be checked.
A special person must be inspected for high-frequency equipment. After opening the door, first discharge the anode, the grid, the capacitor, etc. with a power rod, and then start maintenance, and it is strictly forbidden to repair the electricity.
(6) When using a quenching machine, the safety regulations for electrical, mechanical and hydraulic transmissions should be observed. When moving the quenching machine, prevent it from falling.
2. Safe operation of intermediate frequency and power frequency induction heating equipment
(1) Medium frequency induction heating frequency conversion equipment, there are two types of generator type and thyristor type. The maximum voltage of the intermediate frequency current can reach about 750V, and the safe electricity rules must be observed when using it (the power of the frequency converter is generally greater than 100kW). The IF room should be well ventilated and kept clean, tidy and dry. The IF device must have two people above to be able to boot, and specify the person in charge of the operation. The operator should be familiar with and follow the operating procedures of the intermediate frequency equipment and wear the specified protective equipment. The workpiece should be free of burrs, iron filings and grease stains, otherwise it is easy to produce arcing, and the workpiece should be prevented from coming into contact with the inductor to create arcing during operation. When using medium frequency quenching machines, pay attention to the safe operating procedures of electrical, mechanical and hydraulic transmissions. The equipment needs to be repaired by a special person, and the capacitors are discharged by a discharge rod before repair. It is strictly forbidden to take emergency repairs.
(2) Power frequency induction heating equipment uses industrial electric frequency, low voltage and large current to heat quench or normalize large workpieces. Safety rules should be observed when using.
In order to prevent the large workpiece from being accidentally blown and injured when the power frequency is inductively heated, the operating frequency heat treatment operation rules and the corresponding large-piece heat treatment process rules must be strictly observed during operation. Ultrasonic flaw detection should be carried out on large workpieces one by one. Any workpieces with white spots, severe segregation and looseness after flaw detection are prohibited from heating with power frequency equipment. Workpieces should be deburred, iron filings and oil to prevent arcing. In the production operation, the person in charge must be designated, and the operator must be familiar with and follow the operating procedures of the power frequency equipment.
The workpiece should have lifting holes or suitable clamping stations to ensure the safety of handling and lifting of the workpiece. To operate the power frequency heating machine, pay attention to the safe use rules of electrical and mechanical transmission.
1. Safe operation of high frequency induction heating equipment
The high-frequency induction heating equipment is mainly an electronic (vacuum) tube, which generates high-frequency electromagnetic oscillation. The electric power is 10~200kW, and the highest voltage in the machine is about 15kV. Therefore, it is required that the insulation performance inside the equipment must be good, and the relevant parts such as the casing must be reliably grounded. An insulating rubber mat should be placed at the operating station. Protective wooden railings should be placed next to the equipment, painted with red and white paint. Hang high voltage electric danger sign. The light should be bright and well ventilated at high frequencies, and the indoor temperature should be controlled at 15~35 °C. An air exhaust device is installed to eliminate the soot exhaust gas emitted when the workpiece is heated. Since the frequency of the high frequency device is 30 to 500 KHz, RF radiation is generated. When the body absorbs a certain amount of radiation, biological changes occur. The biological changes increase with the decrease of wavelength (increased frequency) and manifest as neurasthenia syndrome and autonomic nervous system dysfunction. Therefore, shielding measures should be taken for the radiation field sources of the equipment (such as high-frequency transformers, feeders, working capacitors, coupling capacitors and inductors). In order to prevent electromagnetic wave leakage and affect electronic equipment and radio communication in the vicinity (about 100m), the whole room should be shielded, and the radiation intensity of the working environment should be within the specified range (electric field strength E≤20V/m; magnetic field strength H) ≤5A/m. Pay attention to the operation:
(1) There must be two people above to operate the high frequency equipment and specify the person in charge of the operation. Wear insulated shoes, insulated gloves and other protective equipment.
(2) The operator must be familiar with the operating procedures of the high-frequency equipment. Before starting the machine, check whether the cooling system of the equipment is normal, and then send power after normal, and operate according to the operating procedures.
(3) All the doors should be closed before work. The door should be equipped with electrical interlocking device to ensure that the door cannot be powered before it is closed. After the high pressure is closed, it is not allowed to move to the rear of the machine. It is strictly forbidden to open the door.
(4) The workpiece should be free of burrs, iron filings and oil stains, otherwise it will easily arc with the sensor when heated. Arcing now produces arcing that can both damage vision and damage sensors and damage equipment.
(5) High-frequency equipment should be kept clean, dry and free of dust. If abnormal phenomena are found during work, the high-voltage power should be cut off first, and then the fault should be checked.
A special person must be inspected for high-frequency equipment. After opening the door, first discharge the anode, the grid, the capacitor, etc. with a power rod, and then start maintenance, and it is strictly forbidden to repair the electricity.
(6) When using a quenching machine, the safety regulations for electrical, mechanical and hydraulic transmissions should be observed. When moving the quenching machine, prevent it from falling.
2. Safe operation of intermediate frequency and power frequency induction heating equipment
(1) Medium frequency induction heating frequency conversion equipment, there are two types of generator type and thyristor type. The maximum voltage of the intermediate frequency current can reach about 750V, and the safe electricity rules must be observed when using it (the power of the frequency converter is generally greater than 100kW). The IF room should be well ventilated and kept clean, tidy and dry. The IF device must have two people above to be able to boot, and specify the person in charge of the operation. The operator should be familiar with and follow the operating procedures of the intermediate frequency equipment and wear the specified protective equipment. The workpiece should be free of burrs, iron filings and grease stains, otherwise it is easy to produce arcing, and the workpiece should be prevented from coming into contact with the inductor to create arcing during operation. When using medium frequency quenching machines, pay attention to the safe operating procedures of electrical, mechanical and hydraulic transmissions. The equipment needs to be repaired by a special person, and the capacitors are discharged by a discharge rod before repair. It is strictly forbidden to take emergency repairs.
(2) Power frequency induction heating equipment uses industrial electric frequency, low voltage and large current to heat quench or normalize large workpieces. Safety rules should be observed when using.
In order to prevent the large workpiece from being accidentally blown and injured when the power frequency is inductively heated, the operating frequency heat treatment operation rules and the corresponding large-piece heat treatment process rules must be strictly observed during operation. Ultrasonic flaw detection should be carried out on large workpieces one by one. Any workpieces with white spots, severe segregation and looseness after flaw detection are prohibited from heating with power frequency equipment. Workpieces should be deburred, iron filings and oil to prevent arcing. In the production operation, the person in charge must be designated, and the operator must be familiar with and follow the operating procedures of the power frequency equipment.
The workpiece should have lifting holes or suitable clamping stations to ensure the safety of handling and lifting of the workpiece. To operate the power frequency heating machine, pay attention to the safe use rules of electrical and mechanical transmission.
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