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 ranges 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-rectifier options are often deployed to limit harmonic levels when the rating is above 1000kW

A lot many foundries are benefitted from the technically advanced and efficient Twin Power Supply of Megatherm.

The list of features and benefits includes:

• 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 when needed
• 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 for melting individual metals or it can replace multiple twin-share systems.

Melting & Holding Furnaces :

Coreless Steel Frame furnaces:

If your operations desire unquestioned safety &  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 fields to escape the cradle boundaries.  An enhanced degree of electrical insulation shields forms intense electromagnetic 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-zone water
• Silicon steel lamination yokes for shielding
• The top and the bottom refractory castables along with the faraday ring and plate

The setup can easily be dismantled for maintenance purposes.

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 applications. Suitable crucibles are placed for melting metal. Whenever melt is ready, a 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 toward mold with the help of Hand tools. The maximum capacity of the furnaces is  50 kg.

Special Features:

Furnace Lid, Fume Ring & Closed Capture Fume Hood :

Lift and Swing lids 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 the 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 the plant’s exhaust system for specially designed heat resistance and dustproof seal and bearing assembly for Smooth hood motion.

QLR :

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 some steelwork 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.

Pit Guard:

Safety and convenience are yet again offered in the form of a gas spring-supported pit guard. These protective back and site net guards are programmed to shield the furnace pit as the furnace tilts 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 into the furnaces to digitally display the weight, uninterrupted. The central control procession unit is fed with the output from the 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”

KEY HIGHLIGHTS

• Gen 3 furnace incorporates the best aspects of parallel as well as series circuits to give the lowest energy consumption and higher productivity
• Latest SMD-based inverter with a digital interface
• Fibre optics are used in inverters & signal boosting in rectifiers 

• SFC Parameters –Digital display as well as the digital setting of parameters. No need to touch cards.
• Remote Access (virtual SCADA) –All parameters can be viewed and set remotely. Hence, remote diagnosis is possible. Virtual SCADA enables access to all the data & diagnostics on any device.
• Energy Counter –kWh limit for the heat can be set and the counter ticks down. Power can be reduced once the limit has been exhausted.
• Reports –Power, voltage & pressure trends, and graph for post-production analysis,
• Melt analyzer- Daily reporting of no. of heats, total energy consumed, productive time, low power time, downtime & slow charging incidents.
• Auto Diagnostics & Preventive maintenance – All interlocks are displayed digitally. Temperature warning of DM Inlet, SFC outlet, chokes outlet, Capacitor rack outlet, and crucible inlet/ outlet. Hydraulic pressure. Water Conductivity. Automatic maintenance alarms.
• Lining Health Detection System – Patching life status and accident prevention
• Megalink –Remote servicing platform of Megatherm enables solving breakdowns without the physical presence of an engineer 

Packages & Systems: