Induction melting furnace furnace lining maintenance content_Energy saving induction heating equipment manufacturers

The routine maintenance and overhaul of induction melting furnaces is very important. It can detect all kinds of hidden dangers in time, avoid major accidents and ensure long-term safe production, and promote the improvement of casting output and quality.

The maintenance and repair contents of the furnace lining, induction coil, flexible wire, furnace cover, hydraulic system, cooling system and electrical system of induction furnace are listed in the following table. The methods provided in the table are mainly based on the working characteristics of the induction furnace, and many of the contents are also applicable to the grooved induction furnace.

Maintenance and repair project		Maintenance and repair content	Inspection time and frequency	Remarks
furnace lining	Does the lining have cracks?	See if there is any crack	Cold furnace before each furnace	If the crack width is less than 22 mm , if the chips or the like are not embedded in the crack, they do not need to be repaired and can still be used.Otherwise it needs to be patched before it can be used.
	Repair of the taphole	Observe whether there is crack at the junction of the side refurbishment lining and the taphole	When tapping	If there is a crack, repair it
	Repair of furnace bottom and slag line lining	Observe whether the lining of the bottom of the furnace and the slag line is partially corroded.	After tapping	If there is obvious erosion, it needs to be repaired.
sense should line ring	Visual inspection	( 1 ) Is the coil insulation part bumped and carbonized? ( 2 ) Whether there is adhesion to the surface of the coil ( 3 ) Does the insulation pad between the coils protrude? ( 4 ) Is the mounting bolt of the top tight coil loose?	1 time / day 1 time / day 1 time / day 1 time / 3months	Purge with compressed air in the workshop Tighten the bolt
	Coil compression screw	Visually check if the coil compression screw is slack	1 time /week
	rubber tube	( 1 ) Is there any leakage at the rubber pipe joint? ( 2 ) Check if the rubber tube is cut	1 time / day 1 time /week
	Coil corrosion joint	Remove the rubber hose and check the corrosion resistance of the corrosion joint at the end of the coil	1 time / 6months	When the corrosion joint is corroded by 1/2or more, it needs to be replaced with a new one.Usually changed every two years
	Cooling water temperature at the coil outlet	Under the rated amount of molten iron and rated power, record the maximum and minimum cooling water temperature of each branch of the coil	1 time / day
	Dust removal	There is compressed air in the workshop to blow off the dust and molten iron on the surface of the coil.	1 time / day
	Pickling	Pickling of the sensor water pipe	1 time / 2years
can scratch Sex guide line	Water cooled cable	( 1 ) Whether there is leakage ( 2 ) Check if the cable is in contact with the pit ( 3 ) Record the cable outlet temperature at rated power ( 4 ) Preventive measures taken to prevent accidents ( 5 ) Check if the connection bolts at the terminal end are discolored	1 time / day 1 time / day 1 time / day 1 time / 3years 1 time / day	According to the number of tilting, the life of the water-cooled cable is determined to be three years. It needs to be replaced after three years. If the bolt is discolored, re-tighten.
Maintenance and repair project		Maintenance and repair content	Inspection time and frequency	Remarks
furnace cover	Dry cable	( 1 ) Eliminate dust on the busbar splint of insulating rubber ( 2 ) Check if the chain of the suspension busbar is broken ( 3 ) Is the busbar copper foil disconnected?	1 time / day 1 time /week 1 time /week	When the copper foil area is 10% of the busconductive area , a new busbar needs to be replaced.
	Refractory pouring material	Visual inspection of the refractory lining inspection lid watering a layer thickness	1 time / day	When the thickness of the refractory potting material is 1/2, the lining of the furnace cover should be rebuilt.
	Hydraulic furnace cover	( 1 ) Whether there is leakage at the sealing part ( 2 ) Leakage of piping ( 3 ) Leakage of high pressure pipe	1 time / day 1 time / day 1 time / day	If so, repair it Exchange
	High pressure pipe	( 1 ) There are traces of iron scald on the high-pressure pipe, etc. ( 2 ) To ensure safety, exchange	1 time /week 1 time / 2years
	Lubricating	( 1 ) Manual type: part of the fulcrum of the furnace cover ( 2 ) Electric type: sprocket drive bearing for shaft adjustment chain for shaft cover wheel ( 3 ) Hydraulic type: guide bearing
pour move oil Cylinder	Cylinder lower bearing and high pressure pipe	( 1 ) There are traces of iron scald on the bearing part and the high pressure pipe ( 2 ) oil leakage	1 time /week 1 time /month	Remove the cover for inspection
	Cylinder	( 1 ) Whether there is leakage at the sealing part ( 2 ) abnormal sound	1 time / day 1 time / day	Observe the cylinder block when tilting the furnace When a sound such as a knocking cylinder is issued, most of the bearings are short of oil.
	Inclined limit switch	( 1 ) Action check Press the limit switch by hand and the pump motor should stop running. ( 2 ) Whether there is splashing molten iron on the limit switch	1 time /week 1 time /week
	Lubricating	All the fuel filler ports	1 time /week
High pressure control cabinet	Cabinet inspection	( 1 ) Check the operation of each indicator bulb ( 2 ) Whether the parts are damaged or burned out ( 3 ) Clean the inside of the tray with compressed air in the workshop	1 time /month 1 time /week 1 time /week
High pressure control cabinet	Circuit breaker vacuum switch	( 1 ) Cleaning pass is the contact The vacuum tube is milky white, blurred, and the vacuum is reduced. ( 2 ) Measuring electrode consumption	1 time / 6months 1 time /month	If the gap exceeds 6 mm,replace the vacuum tube
Main switch cabinet	Electromagnetic air switch	( 1 ) The roughness of the main contact, the amount of wear ( 2 ) Come on ( 3 ) Whether the fire extinguishing board has carbonization	1 time / 6months 1 time / 6months 1 time / 6months	Grinding with a trowel, sand, etc. When the contact wear exceeds 2/3 , change the contact Adding spindle oil to each bearing and link The carbonized part is ground with sand
Maintenance and repair project		Maintenance and repair content	Inspection time and frequency	Remarks
Main switch cabinet		( 4 ) Dust removal	1 time /week	Clean with compressed air in the workshop and wipe off the dust on the insulator with a cloth
Main switch cabinet	Insulation resistance	Use a 1000 volt megger to measure the main loop with greater than 10M Ωbetween
Converter switch	Transfer switch	( 1 ) Measuring insulation resistance ( 2 ) switch main joint rough ( 3 ) The main circuit connecting bolt is loose and overheated	1 time / 6months 1 time /month 1 time / 3months	Measuredbetween the conductor and the ground with a 1000volt megger 1M Ω Polish or exchange
control system cabinet station	Cabinet inspection	( 1 ) Whether the component is damaged or burned out ( 2 ) Whether the component is slack or falling off	1 time /week 1 time /week
	Action test	( 1 ) Check if the indicator light is on ( 2 ) Alarm circuit Should check the action according to the alarm condition	1 time /week 1 time /week
	Dust removal inside the cabinet	Use workshop compressed air to clean	1 time /week
	Auxiliary machine contactor	( 1 ) Check the roughness of the joint, and use a fine sand to smooth it when it is rough. ( 2 ) Exchange contacts Replace when the contact is worn out	1 / March 1 time / 2years	In particular, the contactor for the furnace cover that is often used
Transformer reactor	Check appearance	( 1 ) Is there any oil leakage? ( 2 ) Whether the insulating oil is added to the specified position	1 time /week 1 time /week
	Transformer and reactor temperature	Check the daily thermometer indication, below the specified value	1 time /week
	Sound and vibration	( 1 ) usually check by listening and touching ( 2 ) Instrument measurement	1 time /week 1 time /year
	Insulating oil pressure test	Should meet the specified value	1 time / 6months
	Tap changer	( 1 ) Check the tap conversion for offset ( 2 ) Check the roughness of the tap adapter	1 time / 6months 1 time / 6months	Change the new one when it is severely rough with fine sand
Capacitor bank	Check appearance	( 1 ) Is there any oil leakage? ( 2 ) Whether the terminal screws are loose or not	1 time / day 1 time /week	If slack occurs , theterminal part will change color due to overheating.
	Replacing the contactor of the capacitor Dust removal	( 1 ) Rough joint 1 ) Smooth the rough part with a trowel sand 2 ) When the wear is severe, change the joint ( 2 ) Contact temperature rise Wipe the insulator with a cloth using a compressed air in the workshop	1 time / 6months 1 time /week 1 time /week	At least 1 time/ month
	Temperature around the capacitor bank	Mercury thermometer measurement	1 time / day	Ventilated, so that the surrounding temperature does not exceed 40 ℃
Oil pressure device	Hydraulic oil	( 1 ) Whether the oil level of the oil level indicates the color of the oil changes ( 2 ) Check the amount of dust in the hydraulic oil and the quality of the oil ( 3 ) Measuring temperature	1 time /week 1 time / 6months 1 time / 6months	If the oil level drops ,the circuit leaks When the quality is poor , change the oil.
Oil pressure device	pressure gauge	Whether the pressure of the tilting furnace is different from normal, when the pressure drops, adjust the pressure to normal value.	1 time /week