Foundry Applications :
Induction furnaces are widely used for ferrous and non – ferrous for automobile castings, DI pipe castings, manganese steel castings, heavy engineering castings, railway component casting, roll manufacturing, steel shots making, grinding media casting etc. We address to the following ferrous and non – ferrous foundry sectors:
Iron & Steel Casting Units :
* Grey and Cast Iron Melting
* Steel and Alloy Steel Melting
* Stainless steel Castings
* Holding and Super Heating
Non-Ferrous Casting units : Special Applications :
* Aluminium Melting * Precious Metal like Gold, Silver etc Melting
* Copper Melting * Investment Casting
* Brass / Bronze Melting * Laboratory Application
Induction Power Supply Unit :
When it comes to Induction Melting Power Source units, Megatherm has a commendable series to offer. These power units are fitted with the much trusted ‘parallel resonant current fed technology’ that ensures the most efficient and reliable melting. The capacity of these units range between 15Kw and 20MW matched by similar gradation in operating frequency -100Hz to 9600Hz. The power semiconductor devices in the circuits are customized either with fast thyristors or IGBTs depending on the power and the frequency.
With the purpose of controlling the frequent downward regulation of power, D.C Choppers are also utilized to maintain constant mains power factor under all operating conditions. Multi-pulse and multi-rectifiers options are often deployed to limit harmonic levels when the rating is above 1000kW
A lot many foundries are benefitted with the technically advanced and efficient Twin Power Supply of megatherm. The list of features and benefits include:
* Highest productivity
* Optimum utilization of furnaces
* Sharing of rated power at any given ratio
between two furnaces
* Parallel utilization of the twin crucibles for
melting and holding/super-heating as and
* Explicitly controlled power sharing mechanism
facilitating absolute energy utilization
* User friendly operation
Megatherm’s multi-share power supply has flexibility for sharing of rated power at any given ratio between multiple furnaces of different operating frequencies. It also comes with the advantage of using different furnaces of melting individual metals or it can replace multiple twin-share system.
Melting & Holding Furnaces :
Coreless Steel Frame furnaces:
If your operations desire unquestioned safely & competence coupled with high energy efficiency then Megatherm’s Steel Frame Furnace is the solution for you. Designed suitably to perform the best in low to high power density, these steel frame furnaces are low on maintenance, high on shielding magnetic fluxes and offer extremely rugged construction.
Run on the latest Electromagnetic Software programs these furnaces certify and care for their human operators. Strong faraday rings and distributed flux guides prevent intense electromagnetic field to escape the cruddle boundaries. An enhanced degree of electrical insulation shields form intense electro-magnetic fields. The software also facilitates optimal impedance to go with the power source as well as a rapid melting rate undeterred by the loose initial charges.
A steel frame takes shape when a coils cradle assembly and tilting and supporting frame gets linked with a pair of hydraulic cylinders, aiding in lip axis pouring. The components in a coil cradle assembly are.
* Electrolytic copper coils cooled in single or multi
* Silicon steel lamination yokes for shielding
* The top and the bottom refractory castables along with faraday ring and plate
The set up can easily be dismantled for maintenance purpose.
For both melting and holding applications of a given power and melt size, frequency and crucible geometries are appropriately selected to provide optimum stirring and lining life.
Pop-up Furnaces :
This Furnace is specially designed for small capacity non – ferrous melting for laboratory application or for precious metal casting application. Suitable crucibles are place for melting metal. Whenever mellt is ready, crucible (made of graphite, silicon carbide etc) containing liquid metal will be lifted out through pneumatic operation so that it can be easily carried out towards mould with the help of Hand tools. Maximum Capacity of the furnaces is 50 kg.
Furnace Lid, Fume Ring & Closed Capture Fume Hood :
Lift and Swing lid in addition to stationary fume rings serve the dual purpose of energy preservation as well as pollution control. The lids are manually as well as hydraulically operated, whereas the end of the fume being is connected to duct of the plant’s exhaust system.
Hydraulically operated close capture fume heads are also available for large capacity furnaces. These are double acting and open on both sides to facilitate charging and pouring. The duct end is connected with plant’s exhaust system for specially designed heat resistance and dust proof seal and bearing assembly for Smooth hood motion.
Megatherm is always a step ahead of its competitors in terms of convenience. It has released the furnace maintenance team from the hassle of manually removing the old lining. A specially crafted device comprising of some steel work and a block at the bottom of the crucible takes care of the job. A hydraulic cylinder is assigned to push the block and quickly extract the lining.
Back – Tilting :
It has often been noticed that the process of slag – removal is a laborious one in the conventional mode of larger furnaces. Thus the back-tilting facility introduced by Megatherm is an immensely popular and convenient arrangement of scraping out slag in the receiving trolley in lesser time.
Safety and convenience is yet again offered in the form of gas spring supported pit guard. These protective back and site net guards are programmed to shield the furnace pit as the furnace tilted to tab liquid metal. This mechanism wards off accidents.
Load Cell Arrangement :
The furnace operation is further integrated and automated with the continuous metal weighing system the cutting-edge technology is in-built in the furnaces to digitally display the weight, uninterrupted. The central control procession unit is fed with the output from load cell to facilitate centralized automated operation.
Generation 3 Melting Furnace
Introducing generation 3 induction furnaces for highest productivity and lowest energy consumption. Minimize downtime by using PLC based auto diagnostics, preventive maintenance and remote servicing”
Packages & Systems:
|Diagnostics Package||Continuous temperature and pressure sensing at critical points for pre and post incident diagnostics|
|Operations Package||Energy Counter, Melt Analyzer|
|Maintenance Package||Water Conductivity, Automatic Maintenance Alarms|
|Accident Prevention System||Digital GLD, Lining Health Detector, Bottom Earth Leakage Sensor|
|Remote Access||Virtual Scada accessible via any device from anywhere|
|Megalink||Remote servicing of furnace|