一、概述、

感應電流和磁場作用產生電磁推力，因為該推力沿行波磁場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，起到攪拌的作用，這種現象被稱為電磁攪拌。其重要目的是混合金屬溶液，以產生更好的均質合金。

攪拌的總量決定于爐子的大小，加入金屬溶液的功率，電磁場的頻率以及爐內金屬熔的種類和質量。攪拌的缺點是它會使爐的耐火爐襯，因攪動金屬熔液碰撞在爐壁上而漸漸地出現磨損。漸漸磨損的結果就要求定期更換爐襯。 當爐襯已被磨損到其規定的最小厚度時， 為了防止爐襯失效， 應迅速更換。

優點為具有對被熔化溶液有攪拌作用,使溶液更均勻混合?？墒谷垠w上下部的溫度均勻，攪拌過程不破壞氧化層，可減少熔體的吸氫及吸氧，確保熔體質量，實現復雜合金的成分均勻化。電磁攪拌是靠電磁力對金屬熔液非接觸的攪拌，不存在攪拌過程中對熔體的污染。

二、功能的實現原理：采用2組線圈實現上下攪拌，任何攪拌狀態下攪拌強度、攪拌時間，攪拌方向，單個線圈的工作時間、都可以在熔煉控制系統內設定，并實現精準的PID溫度控制。

三、智能控制系統說明

智能控制系統可以對中頻加熱設備和機械裝置進行集中控制，它置于生產現場，有利于對加熱工藝的全過程進行控制。在此基礎之上，配置有接觸式測溫裝置（熱電偶）與PLC編程模塊，可以實現根據鋁熔液溫度控制和中頻電源功率控制,以及攪拌強度、攪拌時間，攪拌方向的控制。

四、PID溫度閉環控制系統

   采用國際先進的PID溫度閉環控制系統，熱電偶測溫，溫度精度±５℃。

五、感應線圈說明

感應線圈用銅管繞成。為了保證感應線圈的可靠性，銅管采用了5mm厚,純度為99.99%，材質為T2的優質冷擠制銅管。感應線圈的形狀和空間結構根據電磁感應數值模擬優選的結果來設計。2個線圈順時針逆時針繞制。（采用正反繞制避免了線圈之間的縫隙過大產生漏磁）

感應器由水冷銅管、耐火層、保護層等結構組成，其匝數結構通過ANSYS模擬優化得到，來滿足變頻的需要。

六、爐體的設計要求

定點爐體說明

    爐體部份包括感應加熱線圈、結構主體碳鋼、加磁軛，絕緣體、耐熱絕熱材料、支承框架、定點澆鑄結構等?！?/span>

爐體定點澆鑄結構安裝在支承框架上，根據甲方提供的霧化中間包及霧化炮臺尺寸，設計爐體和液壓傾爐機構。此爐體運行速度均勻，爐咀的高差小，出液連續穩定。爐咀的運行曲線，由固定的軌跡，并由電腦優化運算，使用特殊的曲線模板導向鎖定，使爐體從連續出液到定點出液均勻有序進行。爐體傾轉角度：0～95°（0°指爐口為水平位置）；爐翻轉穩定性高，出料口定位精度高（熔煉爐出爐口與漏包的距離小于50mm），澆注中心變動誤差小，霧化澆鋼時爐嘴無前后運動，定點澆注精度高，，前后誤差不超過30mm，同時保證了金屬液流的穩定。成套設備維護更換均采用模塊化設計，易維護易檢修，很大程度提高生產效率。坩堝或打結料的選擇美國天津聯礦的產品能夠耐氟鹽腐蝕以及液態鋁合金沖刷；且不得污染爐內金屬。

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 .