Automatic Induction Forging Equipment

Core Features of Automatic Induction Forging Equipment

1. Intelligent Induction Heating System

• High/Frequency Precision Temperature Control:
  Utilizes IGBT/DSP digital control technology to achieve ±2°C temperature accuracy, with a heating frequency range of 1–100 kHz (dynamically adjustable based on workpiece size and material).
• Non-Contact Electromagnetic Induction:
  Directly heats metal workpieces via alternating magnetic fields, eliminating open flames and oxidation layers while reducing material waste (scale formation reduced by 80%).
• Multi-Zone Independent Temperature Control:
  Segmented heating coil design supports differentiated heating of different workpiece sections (e.g., end preheating + middle through-heating) to meet complex forging process requirements.

2. Fully Automated Process Control

• PLC/HMI Integrated Control:
  Programmable Logic Controller (PLC) + touchscreen Human-Machine Interface (HMI) with pre-set 100+ process recipes, enabling one-click recall and parameter fine-tuning.
• Robotic Loading/Unloading System:
  Paired with industrial robots for automatic loading, flipping, and unloading, achieving a cycle speed of 15–60 times per minute to minimize human intervention.
• Closed-Loop Feedback Regulation:
  Real-time monitoring of current, voltage, and temperature data, with automatic compensation for grid fluctuations to ensure heating consistency (temperature variation ≤±1.5%).

3. High Efficiency, Energy Saving, and Environmental Protection

• Resonant Power Supply Design:
  Power conversion efficiency ≥95%, saving 30–50% energy compared to traditional resistance furnaces, compliant with GB 25324-2020 Energy Efficiency Grade 1 standards.
• Closed-Loop Cooling System:
  Equipped with plate heat exchangers and constant temperature control, ensuring cooling water temperature difference ≤5°C and water resource utilization >90%.
• Low Harmonic Pollution:
  Adopts PWM rectification technology, with Total Harmonic Distortion (THD) <5%, eliminating the need for additional filtering devices.

4. Precision Forging Capabilities

• Uniform Thermal Penetration:
  Specialized coil designs (e.g., multi-turn spiral, saddle-shaped) ensure core-to-surface temperature difference <10°C, preventing the “black core” defect.
• Rapid Heating Rate:
  Reaches forging temperatures (1050–1250°C) within 5–20 seconds, shortening production cycles and increasing capacity (single-piece heating time reduced by 40%).
• Micro Forging Force Control:
  Servo-hydraulic system with pressure accuracy of ±0.5 MPa enables sub-millimeter dimensional control (e.g., φ50mm shaft forging tolerance ≤±0.08mm).

5. Flexible Production Adaptability

• Modular Structural Design:
  Independent configuration of heating, forging, and cooling zones, expandable to 5–8 stations for 联动 (coordinated operation), compatible with workpieces from φ10–φ300mm in diameter.
• Adaptive Process Switching:
  Supports mixed-line production, with AI algorithms automatically matching heating parameters (e.g., power density, heating time), achieving changeover time <15 minutes.
• Custom Tooling Development:
  Dedicated inductor designs for complex workpieces (e.g., gear blanks, blades), enhancing coupling efficiency to over 92%.

6. Safety and Reliability Assurance

• Multiple Protection Mechanisms:
  Automatic alarm and shutdown for over-temperature, over-current, and water shortage, with dual temperature monitoring (infrared + thermocouple) to ensure equipment failure shutdown rate <0.5%.
• Industrial-Grade Durability:
  Uses water-cooled cables (temperature resistance >200°C) and silver-plated copper busbars (conductivity >98% IACS), with key component lifespan >80,000 hours.
• CE/ISO Certification:
  Compliant with EU Machinery Directive 2006/42/EC, EMC Directive 2014/30/EU, and other international standards.