1 Product Positioning

2 Complete System Composition

1. Medium-frequency power cabinet: The power core of the whole system, converts industrial mains alternating current into adjustable medium-frequency alternating current, with output power and frequency matched to steel blanks of different diameters;
2. Compensation capacitor cabinet: Matches resonant circuit to raise power factor, reduce grid reactive loss and guarantee stable full-load long-term output;
3. Induction heating furnace body (inductor): Core heating component. Alternating current passes through customized coils to form high-density alternating magnetic field, generating Joule eddy heat when steel blanks pass through;
4. Feeding & discharging mechanism: Variable-frequency synchronous rollers realize continuous uniform feeding of steel blanks, supporting synchronous conveying of single or multiple blanks;
5. Closed-circuit cooling tower: Supplies constant-temperature circulating cooling water for medium-frequency power supply and induction coils to remove operation heat and ensure long-term continuous operation.

3 Three Technical Designs to Guarantee Uniform Heating of Large Steel Blanks

1. Custom segmented variable-pitch induction coils: Optimize magnetic field spatial distribution according to outer diameter of large steel blanks to avoid local overheating or insufficient heating;
2. Multi-stage heating process: Combine low-frequency deep through-heating and high-frequency surface homogenization. Heat transfers evenly from blank core to surface to realize full through-heating;
3. PLC closed-loop power regulation with infrared thermometers: High-precision infrared temperature probes are installed at inlet and outlet of furnace to collect blank temperature in real time. Power output is automatically adjusted within millisecond level to stabilize consistency of discharging temperature.
    
   Combined control eliminates axial and radial temperature gradient of steel blanks, fully meeting strict skew rolling technical standards of large-diameter wear-resistant steel balls.

4 Power Selection Logic for Large Steel Ball Production Line

5 Common Faults & Daily Maintenance Key Points

1. Coil water leakage and inter-turn insulation breakdown (most frequent faults)
    
   Main causes are rust, scale and oxide scale blockage & corrosion inside cooling pipelines. It is mandatory to regularly clean oxide slag on coil surface, monitor cooling water pressure and flow every day. Water system faults will directly burn expensive IGBT power modules;
2. Aging & capacity drift of resonant capacitors
    
   Capacitors operate under long-term high-frequency resonance, capacity shall be tested periodically. Aged components need timely replacement to prevent system detuning and power drop;
    
   Auxiliary inspection items: Regularly calibrate infrared thermometer accuracy, remove dust inside power cabinet, check synchronization stability of feeding rollers to avoid uneven heating caused by blank collision and deflection.