1 Core Value of Heating Process in Forging

2 Frequency Selection Rules for Induction Heating

1. For steel bars with diameter ≥40mm, medium-frequency power supply of 500–2000Hz is recommended. Low-frequency magnetic field achieves deeper current penetration, transferring heat to the bar core to avoid surface overheating and insufficient internal temperature, realizing full cross-section through-heating.
2. Equipping low-frequency power supply for small bars will reduce heating efficiency and raise equipment investment cost. Calculate the matching relation between workpiece diameter and standard penetration depth before model selection to balance heating effect and cost.

3 Three Measures to Guarantee Uniform Heating

1. Custom variable-pitch induction coils: slow heating at inlet section and rapid temperature rise at outlet, forming gradient heating to reduce axial temperature difference between head and tail;
2. Infrared thermometer + PLC closed-loop control system: collect real-time surface temperature of steel bars and automatically adjust IGBT power output according to temperature deviation;
3. Linkage control of conveying speed and heating power to unify heating rhythm and eliminate temperature difference in the middle and end of bars.

4 Four Energy-Saving Solutions

1. Adopt IGBT transistor power supply: thermal efficiency is over 10% higher than traditional thyristor power supply;
2. Utilize thermal inertia reasonably: reduce power during material change gap instead of full shutdown, cut instantaneous power impact from frequent startup;
3. Maintain coil insulation and cooling circuit: scale and electric leakage cause extra reactive loss; clean pipelines and reinforce insulation regularly;
4. Waste heat recovery: residual heat of coil cooling water can be recycled for workshop heating in winter.

5 Key Daily Maintenance Points

1. Cooling system: only softened pure water is allowed. Test conductivity periodically to prevent scale blockage and burnout of power modules;
2. Resonant capacitor bank: inspect regularly for bulging and oil leakage; capacitor aging is a common cause of power failure;
3. Induction coil: remove oxide scale attached to inner wall timely, otherwise insulation damage and reduced heating efficiency will occur;
    
   Set up regular maintenance records. Preventive maintenance is more cost-effective than emergency breakdown repair to guarantee continuous forging production.