一、概述、

感應(yīng)電流和磁場(chǎng)作用產(chǎn)生電磁推力，因?yàn)樵撏屏ρ匦胁ù艌?chǎng)方向作用并且具有水平分量和垂直分量，可使鋁熔液作傾斜向上或者相下流動(dòng)，起到攪拌的作用，這種現(xiàn)象被稱(chēng)為電磁攪拌。其重要目的是混合金屬溶液，以產(chǎn)生更好的均質(zhì)合金。

攪拌的總量決定于爐子的大小，加入金屬溶液的功率，電磁場(chǎng)的頻率以及爐內(nèi)金屬熔的種類(lèi)和質(zhì)量。攪拌的缺點(diǎn)是它會(huì)使?fàn)t的耐火爐襯，因攪動(dòng)金屬熔液碰撞在爐壁上而漸漸地出現(xiàn)磨損。漸漸磨損的結(jié)果就要求定期更換爐襯。 當(dāng)爐襯已被磨損到其規(guī)定的最小厚度時(shí)， 為了防止?fàn)t襯失效， 應(yīng)迅速更換。

優(yōu)點(diǎn)為具有對(duì)被熔化溶液有攪拌作用,使溶液更均勻混合。可使熔體上下部的溫度均勻，攪拌過(guò)程不破壞氧化層，可減少熔體的吸氫及吸氧，確保熔體質(zhì)量，實(shí)現(xiàn)復(fù)雜合金的成分均勻化。電磁攪拌是靠電磁力對(duì)金屬熔液非接觸的攪拌，不存在攪拌過(guò)程中對(duì)熔體的污染。

二、功能的實(shí)現(xiàn)原理：采用2組線(xiàn)圈實(shí)現(xiàn)上下攪拌，任何攪拌狀態(tài)下攪拌強(qiáng)度、攪拌時(shí)間，攪拌方向，單個(gè)線(xiàn)圈的工作時(shí)間、都可以在熔煉控制系統(tǒng)內(nèi)設(shè)定，并實(shí)現(xiàn)精準(zhǔn)的PID溫度控制。

三、智能控制系統(tǒng)說(shuō)明

智能控制系統(tǒng)可以對(duì)中頻加熱設(shè)備和機(jī)械裝置進(jìn)行集中控制，它置于生產(chǎn)現(xiàn)場(chǎng)，有利于對(duì)加熱工藝的全過(guò)程進(jìn)行控制。在此基礎(chǔ)之上，配置有接觸式測(cè)溫裝置（熱電偶）與PLC編程模塊，可以實(shí)現(xiàn)根據(jù)鋁熔液溫度控制和中頻電源功率控制,以及攪拌強(qiáng)度、攪拌時(shí)間，攪拌方向的控制。

四、PID溫度閉環(huán)控制系統(tǒng)

   采用國(guó)際先進(jìn)的PID溫度閉環(huán)控制系統(tǒng)，熱電偶測(cè)溫，溫度精度±５℃。

五、感應(yīng)線(xiàn)圈說(shuō)明

感應(yīng)線(xiàn)圈用銅管繞成。為了保證感應(yīng)線(xiàn)圈的可靠性，銅管采用了5mm厚,純度為99.99%，材質(zhì)為T(mén)2的優(yōu)質(zhì)冷擠制銅管。感應(yīng)線(xiàn)圈的形狀和空間結(jié)構(gòu)根據(jù)電磁感應(yīng)數(shù)值模擬優(yōu)選的結(jié)果來(lái)設(shè)計(jì)。2個(gè)線(xiàn)圈順時(shí)針逆時(shí)針繞制。（采用正反繞制避免了線(xiàn)圈之間的縫隙過(guò)大產(chǎn)生漏磁）

感應(yīng)器由水冷銅管、耐火層、保護(hù)層等結(jié)構(gòu)組成，其匝數(shù)結(jié)構(gòu)通過(guò)ANSYS模擬優(yōu)化得到，來(lái)滿(mǎn)足變頻的需要。

六、爐體的設(shè)計(jì)要求

定點(diǎn)爐體說(shuō)明

    爐體部份包括感應(yīng)加熱線(xiàn)圈、結(jié)構(gòu)主體碳鋼、加磁軛，絕緣體、耐熱絕熱材料、支承框架、定點(diǎn)澆鑄結(jié)構(gòu)等?！?/span>

爐體定點(diǎn)澆鑄結(jié)構(gòu)安裝在支承框架上，根據(jù)甲方提供的霧化中間包及霧化炮臺(tái)尺寸，設(shè)計(jì)爐體和液壓傾爐機(jī)構(gòu)。此爐體運(yùn)行速度均勻，爐咀的高差小，出液連續(xù)穩(wěn)定。爐咀的運(yùn)行曲線(xiàn)，由固定的軌跡，并由電腦優(yōu)化運(yùn)算，使用特殊的曲線(xiàn)模板導(dǎo)向鎖定，使?fàn)t體從連續(xù)出液到定點(diǎn)出液均勻有序進(jìn)行。爐體傾轉(zhuǎn)角度：0～95°（0°指爐口為水平位置）；爐翻轉(zhuǎn)穩(wěn)定性高，出料口定位精度高（熔煉爐出爐口與漏包的距離小于50mm），澆注中心變動(dòng)誤差小，霧化澆鋼時(shí)爐嘴無(wú)前后運(yùn)動(dòng)，定點(diǎn)澆注精度高，，前后誤差不超過(guò)30mm，同時(shí)保證了金屬液流的穩(wěn)定。成套設(shè)備維護(hù)更換均采用模塊化設(shè)計(jì)，易維護(hù)易檢修，很大程度提高生產(chǎn)效率。坩堝或打結(jié)料的選擇美國(guó)天津聯(lián)礦的產(chǎn)品能夠耐氟鹽腐蝕以及液態(tài)鋁合金沖刷；且不得污染爐內(nèi)金屬。

1. Overview:

Sensing current and magnetic field generate electromagnetic force, because the thrust force acts in the direction along a traveling wave magnetic field and has a horizontal component and a vertical component, the molten aluminum can be inclined upward or fluidized phase, play the role of stirring, a phenomenon It is called electromagnetic stirring. Its important purpose is to mix metal solutions to produce a better homogeneous alloy.

The total amount of agitation depends on the size of the furnace, the kind and quality of the metal solution is added to the power of the furnace and molten metal frequency electromagnetic field. The disadvantage of agitation is that it causes the refractory lining of the furnace to gradually wear out due to the agitation of the molten metal colliding on the wall of the furnace. The result of wear and tear requires regular replacement of the lining. When the lining has been worn to its specified minimum thickness, it should be replaced quickly in order to prevent lining failure.

The advantage is that it has a stirring effect on the melted solution to make the solution more uniformly mixed . The temperature of the upper and lower parts of the melt can be made uniform, the stirring process does not destroy the oxide layer, the hydrogen absorption and oxygen absorption of the melt can be reduced, the melt quality can be ensured, and the composition of the complex alloy can be homogenized. Electromagnetic stirring is the non-contact stirring of the molten metal by electromagnetic force, and there is no contamination of the melt during the stirring process.

2, the implementation principle function of electromagnetic stirring electric furnace: 

using two sets of coils to achieve vertical stirring, stirring in any stirring intensity, the stirring time, stirring direction, the working time of a single coil, can be set within the control system melting, and to achieve accurate temperature PID control.

3 , the intelligent control system description

The intelligent control system can centrally control the intermediate frequency heating equipment and mechanical devices. It is placed on the production site, which is beneficial to control the whole process of the heating process. On this basis, the contact temperature measuring device ( thermocouple ) and the PLC programming module are arranged , which can realize the control according to the aluminum melt temperature control and the intermediate frequency power control , as well as the stirring intensity , the stirring time and the stirring direction .

4, PID temperature closed-loop control system

Adopt international advanced PID temperature closed-loop control system, thermocouple temperature measurement, temperature accuracy ± 5 °C.

5, induction coil description

The induction coil is wound with a copper tube. In order to ensure the reliability of the induction coil, the copper tube adopts a high-quality cold-extruded copper tube with a thickness of 5 mm and a purity of 99.99% and a material of T2. The shape and spatial structure of the induction coil are designed according to the preferred results of electromagnetic induction numerical simulation. The 2 coils are wound clockwise counterclockwise . (The use of forward and reverse winding to avoid excessive gap between the coils to generate magnetic leakage)

The inductor consists of a water-cooled copper tube, a refractory layer, a protective layer, etc., and its number of structures is optimized by ANSYS simulation to meet the needs of frequency conversion.

6, the design requirements of the furnace body

Fixed furnace description

The furnace body part includes an induction heating coil, a structural body carbon steel, a yoke, an insulator, a heat-insulating material, a support frame, a fixed-point casting structure, and the like.

The fixed-point casting structure of the furnace body is installed on the supporting frame, and the furnace body and the hydraulic tilting furnace mechanism are designed according to the size of the atomizing tundish and the atomizing turret provided by the party A. The furnace body runs at a uniform speed, the height difference of the nozzle is small, and the liquid discharge is continuously stable. The running curve of the nozzle is fixed by the trajectory and optimized by the computer. The special curved template is used to guide the locking, so that the furnace body is uniformly and orderly discharged from the continuous liquid discharge to the fixed point. The tilting angle of the furnace body: 0～95° (0° refers to the horizontal position of the furnace mouth); the furnace has high stability of turning, and the positioning accuracy of the discharging port is high (the distance between the outlet and the leakage of the melting furnace is less than 50mm), and the pouring center changes. The error is small. When the atomized steel is poured, there is no back and forth movement of the nozzle. The precision of the fixed point casting is high, and the front and back error does not exceed 30mm, and the stability of the metal liquid flow is ensured. The maintenance and replacement of complete sets of equipment are modular in design, easy to maintain and easy to overhaul, greatly improving production efficiency. Choice of crucible or knotting The products of Tianjin United Mine are resistant to fluoride salt corrosion and liquid aluminum alloy scour; and must not contaminate the furnace metal .