HV255.45i Alternative Energy

FORGING PRESS + INDUCTION FURNACE AND BAR CUTTING DEVICE
Neotecman induction furnace technology employs a combination of proprietary methodology used on an exclusive basis by Neotecman: automatic loading, heating and hot cutting of brass or aluminum bars to be fed at a precisely controlled temperature into the forging press. But this time, the heating of the bars is achieved through a progressive multi-step Electric Induction Equipment tunnel.

The loader automatically lifts the bars from the bundle loader (length 2500-4000mm) onto the roller conveyor. It is important to notice that every single roller is chain driven. This will ensure that the bars are continuously moving, towards the induction area, with no delay, the front tip of the bar being in contact with the trailing edge of the previous bar.

The table is also equipped with a lateral sorting system which will provide for quarantine of non-compliant bars into a lateral storage bin parallel to the table. So, on one side of the roller table we will find the furnace bar loader and on the other side, a parallel, rejected bars storage bin.

The heating area is composed of 3 induction coil units, each one with its independent power supply. Adjustable rollers, driven by servo motors are placed between the inductions coils, and another set of adjustable rollers, installed in the top part of the heating zone, will move down and press the bar to prevent it from skidding while it is going through the induction system. The pressure can be selected and controlled automatically (different pressures for different bar diameters). Pyrometers, placed between the coils take care of the accurate temperature control, constantly adjusting the temperature, while the bars are circulating through each induction coil. The last pyrometer is placed in the cutting area and its main function is to insure bar traceability. Thanks to the pyrometers and sensors, the production rate is constantly adjusted according to the performance of the forging press. In such a way, the whole process is totally automatic and all production steps, as well as the temperature in each coil, are synchronised at each cycle. In case the production rate in the press must suddenly vary, the temperature through the coils and the speed of the bar movement will be adjusted gradually to reach the optimal heating results.

In case of a pause in the forging process, and the bar which is currently in the heating area is short, it will be cut and rejected via the “end of bar” circuit. If, on the contrary, it is still long enough, the system will first put aside (in the parallel storage bar bin) the bar which is pushing on the rolling table, and the rollers between the coils will start moving backwards, evacuating the bar from the heating area, back to the roller tables, and then it will also be sent to the lateral bars storage. After quarantine, it will be determined if the bars may still be used again.

The water-cooling circuit cools down the coils and capacitors during the heating process. Each induction coil is controlled from the independent electric cabinets, that are also cooled down with the same circuit. The cooling circuit is a closed circuit with refrigeration liquid. This liquid is being cooled by a plate style heat exchange, thanks to external cool water from the factory. The cooling pump moves the refrigerating liquid at a rate of 200l/min. There are 2 main independent cooling circuits: one for the electric cabinets, another one for the work-head capacitors, and the last one for the induction coils themselves. Each induction coil has 3 inner circuits (9 in total for 3 coils). All circuits are equipped with an individual sensor system to ensure that the water passes through all crucial points to prevent overheating that would damage the equipment.

In summary, we have developed a high-technology heating system with precise controls to ensure the safety and improved accuracy of the heating process.

The furnace has the capacity to heat up 1000kg/h of brass bars or its equivalent in other alloys.