کوره القای چگونه کار میکند؟

کوره القایی سیستمی است که می تواند تمامی فلزات رسانا را تا حدی گرم کند که تبدیل به مذاب شود. تفاوت اصلی این کوره با سایر کوره های حرارتی در روش گرمایش است. این کوره ها از سیستم گرمایش القایی برای ایجاد نقطه ذوب فلزات مختلف استفاده می کنند.

کوره القای چگونه کار میکند؟

 

کوره القای چگونه کار میکند؟

این وسیله ای است که برای ذوب فلزات استفاده می شود و با گرمایش القایی کار می کند.

اصول کار کوره القایی این است که فلزات رسانا از طریق الکترومغناطیس مذاب می شود.

در گرمایش القایی، تغییرات در شار مغناطیسی ناشی از جریان متناوب و فرکانس صدها کیلوهرتز باعث القای جریان الکتریکی در یک رسانای الکتریکی فلزی می شود که یک جریان گردابی است (این فرآیند شبیه به عملکرد یک ترانسفورماتور است).

گرمایش القایی ثانویه به عنوان یک اتصال کوتاه عمل می کند. در واقع منظور از ثانویه همان فلزی است که مانند اتصال کوتاه عمل می کند و باید گرم شود.

جریان گردابی در فلزات باعث تلفات الکتریکی زیادی می شود که منجر به آزاد شدن شدید گرما می شود. هر چه فرکانس جریان متناوب بیشتر باشد، شدت جریان های گردابی و گرمای تولید شده بیشتر می شود.

در کوره القایی هر چه ماده مورد نظر فرومغناطیسی تر باشد، در نتیجه سیستم گرمایش بیشتر می شود.

کوره القایی چگونه کار میکند؟ | مکامن

 

کوره القایی چگونه کار می کند؟

ابتدا به کمک جریان برق اشتراکی و به کمک مبدل فرکانس جریانی بیش از 1000 آمپر با فرکانس 300 تا 10000 هرتز تولید می شود سپس این جریان به سیم پیچ کوره، سلف یا سیم پیچ ( سیم پیچ القایی). به گونه ای استفاده می شود که هنگام عبور، میدان مغناطیسی با همان فرکانس در وسط سیم پیچ ایجاد می شود.

هنگامی که در وسط یک سیم پیچ از اجسام فلزی رسانا قرار می گیرد، میدان مغناطیسی ایجاد می شود و جریان های گردابی به اجسام القا می شود، این جریان ها جسم را گرم کرده و آن را به ذوب و احتمالاً تبخیر می رساند (در کوره های پوشش). با تغییر فرکانس و قدرت کوره می توان سیستم را برای مصارف مختلف تهیه و استفاده کرد.

تفاوت بین اجاق القایی با سایر کوره ها:

در مقایسه با اجاق گازهای سوخت فسیلی، اجاق گازهای القایی مزایای زیادی از جمله دقت بیشتر، تمیزی و اتلاف حرارت کمتر دارند. به علاوه ابعاد سایر کوره ها بسیار بزرگ بوده و زمان راه اندازی و توقف آن ها طولانی است. کوره های القایی مزایای زیادی از نظر افزایش و کاهش مصرف انرژی دارند. این کوره ها قابلیت ذوب ظرفیت های مختلف از 15 کیلوگرم تا چندین تن را دارند.

در کوره القایی هیچ گونه فعل و انفعال شیمیایی که باعث افزایش آلودگی و تغییر در ترکیب مذاب شود وجود ندارد و علاوه بر آن به دلیل عدم استفاده از الکترود در مقایسه با کوره های قوس الکتریکی امکان مکانیکی وجود ندارد. نفوذ ناخالصی های مادی از نظر توزیع حرارت و کنترل ترکیب مناسب است و از نظر الکتریسیته محدودیتی برای افزایش دما وجود ندارد.

مزایای کوره های القایی:

  • به لطف بخش کنترل الکترونیکی کامل، اپراتور بسیار ساده ای دارد.
  • به دلیل عدم وجود گاز اکسید کننده و شعله، آلودگی و اکسیداسیون وجود ندارد
  • به سرعت شروع به کار می کند و نیازی به پیش گرم کردن یا ذوب اولیه ندارد.
  • سرعت ذوب بالا در مقایسه با کوره های دیگر
  • راندمان قابل توجهی بالاتر از سایر کوره ها
  • توانایی تهیه آلیاژهای همگن به دلیل چرخش در داخل مواد مذاب را دارد.
  • امکان ساخت و نگهداری کوره های ذوب با ظرفیت های مختلف وجود دارد
  • تغذیه و تخلیه آسان
  • امکان کنترل دما بسیار دقیق
  • قابلیت ذوب ضایعات
  • فضای کمی را اشغال می کند
  • دوستدار محیط زیست

برای دیدن آموزش های بیشتر از کانال تلگرامی ما دیدن کنید.

چطور کار میکند

 

دسته بندی کوره القایی:

کوره های القایی بر اساس فرکانس به 3 دسته

1- فرکانس 50 هرتز یا فرکانس اصلی (گاهی اوقات فرکانس سه گانه آنها در همین دسته قرار می گیرد):

آنها عمدتاً در دو نوع آستینی و کانالی ساخته می شوند، دارای تکنولوژی قدیمی و بازده کلی پایین هستند، عمدتاً برای ذوب چدن به دلیل تلاطم زیاد استفاده می شوند (هنوز در برخی از کارخانه ها فعال هستند) این کوره ها معمولاً به عنوان کوره ساعت استفاده می شوند. چدن با ظرفیت چند ده تن مقرون به صرفه است و به عنوان کوره ذوب توصیه نمی شود. این کوره ها را نمی توان با ظرفیت های کم ساخت.

2- فرکانس متوسط ​​که از حدود 200 هرتز تا حدود 10 کیلوهرتز متغیر است.

به عنوان یک قاعده، می توان آنها را به صورت کوره های سریال و کوره های موازی ساخت.

3- فرکانس بالا از 10 کیلوهرتز تا چند مگاهرتز

که به عنوان کوره های ذوب مورد استفاده قرار می گیرند و خصوصیت آزمایشگاهی دارند

تلفات انرژی در کوره های القایی:

راندمان حرارتی یک کوره دوار معمولی 12 تا 15 درصد است. اما راندمان الکتریکی برد مبدل فرکانس حدود 97 درصد و راندمان کلی کوره القایی حدود 75 درصد است که به معنی تا 5 برابر کوره دوار است.

با توجه به اینکه بیشترین تلفات حرارتی در سیم پیچ ذوب رخ می دهد (حدود 18-22%)، ضخامت لوله ذوب و سطح مقطع آن پارامترهای مهمی هستند که باید در نظر گرفته شوند.

حدود 3 درصد تلفات در شیلد مبدل فرکانس و چند درصد در خط ارتباطی و شین های داخل کانال رخ می دهد که برای کاهش تلفات باید سطح عبور جریان الکتریکی را افزایش داد که باعث افزایش مصرف می شود.

مس و هزینه کوره را افزایش می دهد. البته افزایش ضخامت لوله سیم پیچ علاوه بر افزایش سطح جریان عبوری، مزایای دیگری نیز دارد که از آن جمله می توان به افزایش مقاومت مکانیکی سیم پیچ و افزایش مقاومت دیواره لوله در هنگام ذوب اشاره کرد.

نفوذ که در این صورت امکان تنظیم انفجار به میزان قابل توجهی کاهش می یابد.

 

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