Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture
Aim. This article is intended to develop a technique for monitoring the lining state of induction channel furnaces for melting oxygen-free copper by monitoring changes in the distribution of thermal fields in their lining and carrying out a comparative analysis of the developed technique with the...
Gespeichert in:
| Veröffentlicht in: | Електротехніка і електромеханіка |
|---|---|
| Datum: | 2018 |
| Hauptverfasser: | , , , , |
| Format: | Artikel |
| Sprache: | Englisch |
| Veröffentlicht: |
Інститут технічних проблем магнетизму НАН України
2018
|
| Schlagworte: | |
| Online Zugang: | https://nasplib.isofts.kiev.ua/handle/123456789/147634 |
| Tags: |
Tag hinzufügen
Keine Tags, Fügen Sie den ersten Tag hinzu!
|
| Назва журналу: | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| Zitieren: | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture / V.M. Zolotaryov, M.A. Shcherba, R.V. Belyanin, R.P. Mygushchenko, O.Yu. Kropachek // Електротехніка і електромеханіка. — 2018. — № 1. — С. 35-40. — Бібліогр.: 10 назв. — англ. |
Institution
Digital Library of Periodicals of National Academy of Sciences of Ukraine| _version_ | 1859942264061558784 |
|---|---|
| author | Zolotaryov, V.M. Shcherba, M.A. Belyanin, R.V. Mygushchenko, R.P. Kropachek, O.Yu. |
| author_facet | Zolotaryov, V.M. Shcherba, M.A. Belyanin, R.V. Mygushchenko, R.P. Kropachek, O.Yu. |
| citation_txt | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture / V.M. Zolotaryov, M.A. Shcherba, R.V. Belyanin, R.P. Mygushchenko, O.Yu. Kropachek // Електротехніка і електромеханіка. — 2018. — № 1. — С. 35-40. — Бібліогр.: 10 назв. — англ. |
| collection | DSpace DC |
| container_title | Електротехніка і електромеханіка |
| description | Aim. This article is intended to develop a technique for monitoring the lining state of induction channel furnaces for melting
oxygen-free copper by monitoring changes in the distribution of thermal fields in their lining and carrying out a comparative
analysis of the developed technique with the existing one that controls the electrical resistance of the melting channel of the
furnaces. Technique. For carrying out the research, the theories of electromagnetic field, thermodynamics, mathematical physics,
mathematical modeling based on the finite element method were used. Results. A technique for diagnosing the lining state of the
induction channel furnaces for melting oxygen-free copper has been developed, which makes it possible to determine the
dislocation and the size of the liquid metal leaks by analyzing the temperature distribution over the body surface both the inductor
and the furnace. Scientific novelty. The connection between the temperature field distribution on the surface of the furnace body
and the dislocation and dimensions of the liquid metal leaks in its lining is determined for the first time. Practical significance.
Using the proposed technique will allow to conduct more accurate diagnostics of the lining conditions of the induction channel
furnaces, as well as to determine the location and size of the liquid metal leaks, creating the basis for predicting the working life
of the furnace
Цель. Целью статьи является разработка методики контроля состояния футеровки индукционных канальных печей
для плавки бескислородной меди путем мониторинга изменений распределения тепловых полей в их футеровке и
проведение сравнительного анализа разработанной методики с существующей, которая контролирует
электрическое сопротивление плавильного канала печей. Методика. Для проведения исследований использовались
положения теории электромагнитного поля, термодинамики, математической физики, математического
моделирования с применением метода конечных элементов. Результаты. Разработана методика диагностики
состояния футеровки индукционной канальной печи для плавки бескислородной меди, которая позволяет определять
дислокацию и размер протеканий жидкого металла путем анализа распределения температуры по поверхности
корпуса индуктора и печи. Научная новизна. Впервые установлена связь между распределением температурного поля
на поверхности корпуса печи и дислокацией и размерами протеканий жидкого металла в ее футеровке. Практическое
значение. Использование предложенной методики позволит проводить более точную диагностику состояния
футеровки индукционных канальных печей, а также определять расположение и размеры протеканий жидкого
металла, создавая основы для прогнозирования ресурса работы печи
|
| first_indexed | 2025-12-07T16:11:39Z |
| format | Article |
| fulltext |
ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1 35
© V.M. Zolotaryov, M.A. Shcherba, R.V. Belyanin, R.P. Mygushchenko, O.Yu. Kropachek
UDC 621.365.5 doi: 10.20998/2074-272X.2018.1.05
V.M. Zolotaryov, M.A. Shcherba, R.V. Belyanin, R.P. Mygushchenko, O.Yu. Kropachek
COMPARATIVE ANALYSIS OF ELECTRICAL AND THERMAL CONTROL OF THE
LINING STATE OF INDUCTION APPARATUS OF COPPER WIRE MANUFACTURE
Aim. This article is intended to develop a technique for monitoring the lining state of induction channel furnaces for melting
oxygen-free copper by monitoring changes in the distribution of thermal fields in their lining and carrying out a comparative
analysis of the developed technique with the existing one that controls the electrical resistance of the melting channel of the
furnaces. Technique. For carrying out the research, the theories of electromagnetic field, thermodynamics, mathematical physics,
mathematical modeling based on the finite element method were used. Results. A technique for diagnosing the lining state of the
induction channel furnaces for melting oxygen-free copper has been developed, which makes it possible to determine the
dislocation and the size of the liquid metal leaks by analyzing the temperature distribution over the body surface both the inductor
and the furnace. Scientific novelty. The connection between the temperature field distribution on the surface of the furnace body
and the dislocation and dimensions of the liquid metal leaks in its lining is determined for the first time. Practical significance.
Using the proposed technique will allow to conduct more accurate diagnostics of the lining conditions of the induction channel
furnaces, as well as to determine the location and size of the liquid metal leaks, creating the basis for predicting the working life
of the furnace. References 10, tables 3, figures 4.
Key words: induction heating, diagnostics and control, interconnected electromagnetic and thermal processes, thermal field
distribution, three-dimensional mathematical modeling, finite element method.
Цель. Целью статьи является разработка методики контроля состояния футеровки индукционных канальных печей
для плавки бескислородной меди путем мониторинга изменений распределения тепловых полей в их футеровке и
проведение сравнительного анализа разработанной методики с существующей, которая контролирует
электрическое сопротивление плавильного канала печей. Методика. Для проведения исследований использовались
положения теории электромагнитного поля, термодинамики, математической физики, математического
моделирования с применением метода конечных элементов. Результаты. Разработана методика диагностики
состояния футеровки индукционной канальной печи для плавки бескислородной меди, которая позволяет определять
дислокацию и размер протеканий жидкого металла путем анализа распределения температуры по поверхности
корпуса индуктора и печи. Научная новизна. Впервые установлена связь между распределением температурного поля
на поверхности корпуса печи и дислокацией и размерами протеканий жидкого металла в ее футеровке. Практическое
значение. Использование предложенной методики позволит проводить более точную диагностику состояния
футеровки индукционных канальных печей, а также определять расположение и размеры протеканий жидкого
металла, создавая основы для прогнозирования ресурса работы печи. Библ. 10, табл. 3, рис. 4.
Ключевые слова: индукционный нагрев, диагностика и контроль, взаимосвязанные электромагнитные и тепловые
процессы, распределение теплового поля, трехмерное математическое моделирование, метод конечных элементов.
Introduction. Taking into account the constant
increase in energy prices and imported components of
industrial induction apparatus, the urgency of increasing
their resource and energy efficiency, as well as import
substitution of the component equipment, is increasing.
[3, 8]. All these tasks need to be addressed during the
melting of ultrapure oxygen-free copper in induction
channel furnaces, in particular in the UPCAST furnaces
[6], the application of which is expanded due to a number
of technological advantages.
The resource of the UPCAST induction channel
furnaces depends on the duration of the failure-free
operation of the inductor, which heats the liquid metal
channel (0.3 tons), and the furnace, which is above the
inductor and contains most of the liquid melt (up to
10 tons). At present, there is a problem of matching the
resources of the inductor and the furnace. If the predicted
working life of the furnace is 4-6 years, then working life
of the inductor is only 1-2 years, i.e. the technology
includes a planned 2-3-fold replacement of the inductor
design with unchanged furnace design [6, 10].
However, joint experimental studies of PJSC
Yuzhcable Works (Kharkiv) and the Institute of
Electrodynamics of the National Academy of Sciences of
Ukraine (Kiev) using UPCAST line US20X-10 as an
example on the continuous casting of oxygen-free copper
wire have showed that the replacement procedure of the
inductor significantly reduces the working life of the
furnace [8]. Due to the temperature drop from 1150 °C
(the temperature of the copper melt and the furnace lining
surface) up to 300-400 °С (the temperature of furnace
lining after the copper draining during its heating with gas
burners), the lining inevitably cracks. After re-
commissioning the furnace with a new inductor and an
old lining, liquid metal leaks occur in cracks.
The most expedient solution to this problem is to
increase working life of the inductor to working life of the
furnace and use them as a single system during the entire
continuous cycle lasting 4-6 years. As a consequence, the
line resource is expected to increase beyond 4-6 years due
to the lack of planned inductor replacements. The first
step to achieve this goal is to improve the system for
diagnosing the lining thermal state of the inductor and the
furnace.
Now the diagnostics is based on monitoring the
active and reactive inductor resistance by measuring the
impedance of the melting channel and the water
temperature as it passes through the cooling system pipes
[6]. The furnace lining is monitored visually and copper
leaks through lining are inaccessible for inspection and it
36 ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1
is made by measuring the temperature of the furnace
body. This method of diagnostics is indirect, since it does
not allow revealing the location and size of the leaks areas
of liquid metal, and the actual state of the furnace and
inductor is determined by inspection only after they are
completely stopped and cooled.
Therefore, there is a need to develop a new
technique for diagnosing the lining state, which would
allow estimating the direct location and dimensions of the
liquid metal leaks into the lining cracks and thus
predicting working life of the furnace.
The aim of the paper is to develop a technique for
monitoring the lining state of induction channel furnace
for melting oxygen-free copper by monitoring changes in
the distribution of thermal fields in it using a three-
dimensional mathematical model.
Three-dimensional mathematical model.
According to the physical formulation, the problem of
induction heating of a metal consists of
electromagnetic and thermal problems with strong
mutual relations [1, 2, 5, 9].
To calculate the distribution of the magnetic field
and the current density, the system of Maxwell equations
with respect to the vector potential A
is solved.
,rot,rot ABJH
(1, 2)
,grad,)(
t
A
EJETJ ext
(3, 4)
where B
, H
, E
are vectors of magnetic induction,
magnetic and electric fields intensity, J
, extJ
are the
density vectors of the total current and current in the
inductor busbars, φ is the electric scalar potential, σ(T) is
electric conductivity of copper, which is a function of
temperature T and is described by the following
expression:
))(1(
1
)(
0 refTT
T
, (5)
where ρ0 = 1.72·10–8 Ohmm is specific electric resistance
of copper, α = 3.9·10–8 К–1 is its temperature resistance
coefficient, Tref = 273.15 ºК is reference temperature.
The ferromagnetic properties of the magnetic core of
the inductor are described by the magnetization curve:
BBBfH /)(
. (6)
The inductor is connected to a 50 Hz sine voltage
transformer and consumes from 14 to 616 kW. Simulated
processes of continuous heating, especially with primary
starts, can last more than 18 hours. Since the scales of the
electromagnetic and thermal processes on the time axis
differ significantly (20 ms period of electromagnetic
oscillations and more than 64,800 with the heating
duration), then while solving the general interrelated
problem, the electromagnetic subtask is solved in the
frequency domain using the actual values for the
magnetization curve, and the thermal subtask is solved in
the time domain [4].
The calculation equations for various elements of the
inductor are:
for a copper template:
0)(]rot
1
[rot
0
ATjA
, (7)
for copper inductor busbars:
0]rot
1
[rot
0
extJA
, (8)
for steel core:
0]rot
1
[rot
0
A
ef
, (9)
for lining mixture, steel casing, water cooling system
and ambient air:
0]rot
1
[rot
0
A
. (10)
The solutions of equation (7) – (10) were joined on
the boundaries of the elements and were supplemented by
the Dirichlet conditions 0 An
on the boundaries of the
computational domain.
To calculate the heat distribution, the thermal
balance equation is solved:
watereddyp QQTk
t
T
C
, (11)
where ρ, Cp, k are density, heat capacity and thermal
conductivity of materials, Qeddy, Qwater are heat sources,
including the heating of the template by eddy currents
Qeddy (the time average over one period) and cooling of
busbars and lining in the course of water flowing through
the tubes of the cooling system Qwater.
The heat removal through the water was calculated
taking into account the heat capacity of the water, its
temperature and the mass flow:
Qwater = Mt·Cp (Tin − T)/V, (12)
where Mt is water flow in kilograms, passing through the
cross section of the tubes per unit time, Tin is the
temperature of incoming water, V is the internal volume
of the system pipes.
The multi-physical relationship between the
problems of calculating the distributions of magnetic and
thermal fields was realized by using the eddy currents as a
source of heat induced by the magnetic field and
determined according to the solution of the
electromagnetic problem:
22 |/|)(5.0||)(5.0 tATETQeddy
. (13)
Equation (11) was supplemented by conditions on
the boundaries of the computational domain and on the
boundaries of various materials. The convective heat
removal from the inductor and the furnace bodies through
the ambient air was determined at a given heat transfer
coefficient h according to the equation:
)( extTTh
n
Т
k
, (14)
where Тext is the ambient temperature, n is the normal
vector to the outer boundary.
According to the engineering drawings of the
channel furnace used at PJSC Yuzhcable Works, a three-
dimensional model was constructed in the software
ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1 37
package Comsol Multiphysics [4], for which the solution
of the system of differential equations (7) – (11) was
found by the finite elements method.
Comparative analysis of electrical and thermal
control. Lining furnace is formed by four layers of brick,
where the first and second layers serve as «armor» and
keep the metal melt from leaks. In this case, the
temperature difference at the boundaries of these layers is
119 °C (from 1150 to 1031 °C). The third and fourth
layers perform the functions of the heat insulator and the
main temperature drop at 899 °C (from 1031 to 132 °C)
occurs on their boundaries [6]. However, because of the
porous structure, the third and fourth layers of brick after
penetration of the metal melt through the «armor»
actively absorb it, which eventually leads to the metal
flow to the outer steel body of the furnace. As a result,
even drops of liquid copper may appear, emerging
through its technological holes. Because of this, areas of
high temperature rise appear on the body. Such processes
increase the power consumption, i.e. reduce the energy
efficiency of the entire production process and
significantly reduce working life of the furnace.
At the moment, the diagnostics of its resource is
carried out by monitoring and recording the active R and
reactive X of the inductor resistance. Fig. 1,a shows black
dots which are the results of measuring the impedance Z
of the melting channel of the inductor at PJSC Yuzhcable
Works for the period from 01.2013 to 09.2017.
a
S
r
5
4
3 2
1
b
Fig. 1. Measurements of impedance Z of the melting channel of
the inductor at PJSC Yuzhcable Works (a); the shape of the
melting channel and its possible defects (b)
The active resistivity of the R channel is plotted in
ohms along the ordinate axis and its reactive resistance X.
The value of R varies inversely with the cross-sectional
area of the channel S in Fig. 1,b (R ~ 1/S). The value X
has an inductive character and is proportional to the
channel radius (X ~ r). The region bounded by the
quadrilateral in Fig. 1,a is the region of values of the
impedance Z of the channel during normal operation of
the inductor. The deviation of the measured values of Z
beyond the limits of the quadrilateral indicates the
emergency operation of the induction apparatus, which is
connected with the flow of the melt into the lining of the
furnace or vice versa by the entrapment of the melting
channel slags in the inductor.
Table 1 shows the change in the parameters R, X,
and Z for each of the five types of melting channel defects
shown in Fig. 1,b.
Table 1
The change of the parameters R, S and Z of the melting channel
for each of the five types of its defects
R~1/S Х ~r Z
1 ↑ ↑
2 ↓ ↑
3 ↓ ↓
4 ↑ unchanged
5 ↓ unchanged
Also, the existing diagnostics system includes
monitoring the change in the temperature T of the running
water in the cooling system. The system has 4 water-
cooled circuits, the tubes of this circuit pass along the
surface of the furnace adjoining to the inductor, along the
surface of the cylindrical inductor holes for the magnetic
circuit, inside the copper busbars and the inductor body
base. According to the technical documentation, if the
difference in ΔT across all circuits remains within 5 °C,
then the line condition is considered normal.
To improve the diagnostics system, it was suggested
to monitor not only the system-specific parameters
(impedance Z and temperature difference ΔT), but also the
temperature distribution along the inductor and furnace
bodies. The task was to develop a mathematical model
and a technique for calculating the temperature
distributions both on the body surface and inside the
lining of the inductor and furnace in nominal and
emergency operation modes. The verification of the
model was carried out by comparing the isotherms
38 ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1
calculated on the body with the real ones measured on the
operating casting line.
According to the developed method, with a non-
uniform temperature distribution on the surface of the
metal casings of the furnace and inductor, temperature
changes in local areas and sizes of such areas are
monitored. Then, the model determines the shape and size
of the melt flowing in the furnace lining and inductor to
obtain isotherms that coincide with the experimental ones.
With the help of this approach, the instantaneous state of
the furnace is diagnosed.
Table 2
The measurement results of the values Tmin, Tmax and ΔT
in the cathode loading zone
The cathode loading zone, Tmin, °C
1 2 3 4 5 6 7 8 9
1 70 95 75 78 115 115 70 70 71
2 101 89 105 105 105 105 70 70 56
3 92 96 95 130 124 99 79 79 60
4 70 85 85 95 95 99 80 80 74
The cathode loading zone, Tmax, °C
1 2 3 4 5 6 7 8 9
1 95 78 77 96 95 95 98 65 95
2 105 90 105 105 105 105 70 69 64
3 105 91 135 152 124 120 79 80 68
4 95 96 91 108 90 88 83 82 79
The cathode loading zone, ΔT, °C
1 2 3 4 5 6 7 8 9
1 25 0 2 18 0 0 1 0 24
2 4 1 0 0 0 0 0 0 8
3 13 5 45 22 0 21 0 1 8
4 25 11 6 13 0 0 3 2 5
Table 3
The measurement results of the values Tmin, Tmax and ΔT
in the wire drawing zone
The wire drawing zone, Tmin, °C
1 2 3 4 5 6 7 8 9
1 75 72 77 81 101 87 91 95 95
2 62 62 75 119 119 11 129 118 105
3 71 88 143 127 115 115 128 145 117
4 92 109 124 75 122 120 101 99 71
The wire drawing zone, Tmax, °C
1 2 3 4 5 6 7 8 9
1 105 105 110 110 102 105 130 110 115
2 106 118 130 226 150 151 160 163 125
3 120 148 242 215 180 190 199 201 141
4 140 200 254 170 202 170 182 154 108
The wire drawing zone, ΔT, °C
1 2 3 4 5 6 7 8 9
1 30 45 33 29 20 18 39 15 5
2 44 56 55 107 31 40 31 45 20
3 49 60 99 88 65 75 71 56 24
4 48 91 130 95 80 50 81 55 37
To predict working life of the furnace, a study was
made on the change in the isotherms on the furnace body
after a long operating time. An experiment with duration
of 3.5 years (from 04.2014 to 09.2017) was planned and
conducted to measure the temperature T on the inductor
body and the line furnace. The main attention was paid to
the furnace, since it contains the bulk of the melt.
The furnace body was divided into 72 control zones
(36 in the section for loading copper cathodes for melting
and 36 for the stretching of the copper wire), in which the
temperature T was measured by an optical pyrometer.
Table 2 for the cathode loading zone and Table 3 for
the wire drawing zone show the measurement results of
the minimum temperature Tmin (measured in 2014), the
maximum temperature Tmax (observed from 2014 to 2017)
and the temperature difference ΔT reflecting the increase
in the average operating temperatures in the zones due to
the melt flowing into the lining.
а
b
c
Fig. 2. The measurement results of the values Tmin, Tmax and ΔT
in the cathode loading zone
ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1 39
The measurement results are plotted accordingly in
the diagrams in Fig. 2 and Fig.3, where the height and
color of the peaks demonstrate the location and
temperature of the zones of the furnace body. Fig. 2,a and
Fig. 3,a show the temperature distribution measurements
Tmin according to measurements made in 2014, when the
furnace lining had a small number of defects. Fig. 2,b and
Fig. 3,b show the distribution of the maximum
temperature Tmax, which was observed for 3.5 years of
industrial operation of the furnace. Fig. 2,c and Fig. 3,c
reflect the temperature increase over the body ΔT due to
the lining degradation.
a
b
c
Fig. 3. The measurement results of the values Tmin, Tmax and ΔT
in the wire drawing zone
Fig. 4 shows graphs of temperature increase T in
time in the four hottest control points.
Temperature changes T, C in control points
M
ar
ch
2
01
4
Ju
ne
2
01
4
O
ct
ob
er
2
01
4
Fe
br
ua
ry
2
01
5
Ju
ne
2
01
5
O
ct
ob
er
2
01
5
Fe
br
ua
ry
2
01
6
Ju
ne
2
01
6
O
ct
ob
er
2
01
6
Fe
br
ua
ry
2
01
7
p.33 p.34 p.43 p.37
Fig. 4. Temperature increase T in time in the four hottest control
zones
Comparing the experimental results in Fig. 2 and
Fig. 3, we note that in the wire drawing zone higher
temperatures are observed, and this can be seen in both
minimum and maximum values. If in the cathode loading
zone the average values are Tmin av1 = 82 °C and Tmax av1 =
= 101 °C, then in the wire drawing zone these values are
Tmin av2 = 96 °C and Tmax av2 = 154 °C.
It was determined that during the operation of the
furnace, the average temperature on its body increased by
58 °C (from 96 °C to 154 °C). At the same time, in the
wire drawing zone, the maximum temperature is 254 °C,
as shown by the peak in Fig. 3,b, and three zones of the
greatest temperature increase (to 130, 107, and 81 °C),
which is shown by the three peaks in Fig. 3,c. Such an
increase in temperature indicates the presence of several
zones of liquid metal flowing into the furnace lining and
its degradation in the future.
Conclusions.
1. The method of monitoring the lining state of
induction channel furnaces for melting oxygen-free
copper is well-reasoned by monitoring changes in the
distribution of thermal fields in their lining. According to
the proposed method, the temperature and location of the
hottest areas are measured on the furnace body, according
to which, using a three-dimensional mathematical model,
the shape and size of the metal melt flowing into the
lining is determined.
2. As a result of the planned experiment (lasting 3.5
years) and controlling the change in temperature T in 72
control zones of the furnace casing and inductor of the
casting line of the copper wire UPCAST US20X-10 at
PJSC Yuzhcable Works, regions of greatest temperature,
temperature gradients on the body, and also their
variations with time are detected.
3. It was determined that during the operation of the
furnace, the average temperature on its body increased by
58 °C (from 96 °C to 154 °C). At the same time, in the
wire drawing zone, the maximum temperature was
254 °C, as shown by the peak in Fig. 3b, and three zones
of the greatest temperature increase (to 130, 107, and
81 °C), which indicates the presence of several zones
leaks in lining furnace
4. The use of the proposed technique allows more
accurate diagnostics of the lining state of the induction
40 ISSN 2074-272X. Електротехніка і Електромеханіка. 2018. №1
channel furnaces, as well as determining the location and
size of the liquid metal flow, creating the basis for
predicting the working life of the furnace.
REFERENCES
1. .Bermúdez A., Gómez D., Muñiz M.C., Salgado P., Vázquez
R. Numerical simulation of a thermo-electromagneto-hydro-
dynamic problem in an induction heating furnace. Applied
Numerical Mathematics, 2009, vol.59, no.9, pp. 2082-2104. doi:
10.1016/j.apnum.2008.12.005.
2. Gleim T., Schröder B., Kuhl D. Nonlinear thermo-
electromagnetic analysis of inductive heating processes. Archive
of Applied Mechanics, 2015, vol.85, no.8, pp. 1055-1073. doi:
10.1007/s00419-014-0968-1.
3. Lucia O., Maussion P., Dede E.J., Burdio J.M. Induction
heating technology and its applications: past developments,
current technology, and future challenges. IEEE Transactions on
Industrial Electronics, 2014, vol.61, no.5, pp. 2509-2520. doi:
10.1109/TIE.2013.2281162.
4. Pepper D.W., Heinrich J.C. The Finite Element Method:
Basic Concepts and Applications with MATLAB, MAPLE, and
COMSOL. CRC Press, 2017. 610 p.
5. Stegmueller M.J.R., Schindele P., Grant R.J. Inductive heating
effects on friction surfacing of stainless steel onto an aluminum
substrate. Journal of Materials Processing Technology, 2015,
vol.216, pp. 430-439. doi: 10.1016/j.jmatprotec.2014.10.013.
6. UPCAST, Finland. Available at: http://www.upcast.com
(accessed 10 May 2017).
7. Hadad Y., Kochavi E., Levy A. Inductive heating with a
stepped diameter crucible. Applied Thermal Engineering, 2016,
vol.102, pp. 149-157. doi: 10.1016/j.applthermaleng.2016.03.151.
8. Zolotaryov V.M., Belyanin R.V., Podoltsev O.D. Analysis
of electromagnetic processes in the induction channel furnace
used in the cable industry. Works of the Institute of
Electrodynamics of the National Academy of Sciences of
Ukraine, 2016, vol.44, pp. 110-115. (Rus).
9. Shcherba A.A., Podoltsev O.D., Kucheriava I.M., Ushakov
V.I. Computer modeling of electrothermal processes and
thermo-mechanical stress at induction heating of moving copper
ingots. Technical Electrodynamics, 2013, no.2, pp. 10-18. (Rus).
10. Zolotaryov V.M., Shcherba M.A., Belyanin R.V. Three-
dimensional modeling of electromagnetic and thermal processes
of induction melting of copper template with accounting of
installation elements design. Technical Electrodynamics, 2017,
no.3, pp. 13-21. (Rus).
Received 07.11.2017
V.M. Zolotaryov1, Doctor of Technical Science,
M.A. Shcherba2, Candidate of Technical Science,
R.V. Belyanin1,
R.P. Mygushchenko3, Doctor of Technical Science,
O.Yu. Kropachek3, Candidate of Technical Science,
1 Private Joint-stock company Yuzhcable works,
7, Avtogennaya Str., Kharkiv, 61099, Ukraine,
phone +380 57 7545228, e-mail: zavod@yuzhcable.com.ua
2 The Institute of Electrodynamics of the NAS of Ukraine,
56, prospekt Peremogy, Kiev-57, 03680, Ukraine,
phone +380 44 3662460, e-mail: m.shcherba@gmail.com
3 National Technical University «Kharkiv Polytechnic Institute»,
2, Kyrpychova Str., Kharkiv, 61002, Ukraine,
phone +380 57 7076116, e-mail: mrp1@ukr.net
|
| id | nasplib_isofts_kiev_ua-123456789-147634 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 2074-272X |
| language | English |
| last_indexed | 2025-12-07T16:11:39Z |
| publishDate | 2018 |
| publisher | Інститут технічних проблем магнетизму НАН України |
| record_format | dspace |
| spelling | Zolotaryov, V.M. Shcherba, M.A. Belyanin, R.V. Mygushchenko, R.P. Kropachek, O.Yu. 2019-02-15T11:06:32Z 2019-02-15T11:06:32Z 2018 Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture / V.M. Zolotaryov, M.A. Shcherba, R.V. Belyanin, R.P. Mygushchenko, O.Yu. Kropachek // Електротехніка і електромеханіка. — 2018. — № 1. — С. 35-40. — Бібліогр.: 10 назв. — англ. 2074-272X DOI: https://doi.org/10.20998/2074-272X.2018.1.05 https://nasplib.isofts.kiev.ua/handle/123456789/147634 621.365.5 Aim. This article is intended to develop a technique for monitoring the lining state of induction channel furnaces for melting oxygen-free copper by monitoring changes in the distribution of thermal fields in their lining and carrying out a comparative analysis of the developed technique with the existing one that controls the electrical resistance of the melting channel of the furnaces. Technique. For carrying out the research, the theories of electromagnetic field, thermodynamics, mathematical physics, mathematical modeling based on the finite element method were used. Results. A technique for diagnosing the lining state of the induction channel furnaces for melting oxygen-free copper has been developed, which makes it possible to determine the dislocation and the size of the liquid metal leaks by analyzing the temperature distribution over the body surface both the inductor and the furnace. Scientific novelty. The connection between the temperature field distribution on the surface of the furnace body and the dislocation and dimensions of the liquid metal leaks in its lining is determined for the first time. Practical significance. Using the proposed technique will allow to conduct more accurate diagnostics of the lining conditions of the induction channel furnaces, as well as to determine the location and size of the liquid metal leaks, creating the basis for predicting the working life of the furnace Цель. Целью статьи является разработка методики контроля состояния футеровки индукционных канальных печей для плавки бескислородной меди путем мониторинга изменений распределения тепловых полей в их футеровке и проведение сравнительного анализа разработанной методики с существующей, которая контролирует электрическое сопротивление плавильного канала печей. Методика. Для проведения исследований использовались положения теории электромагнитного поля, термодинамики, математической физики, математического моделирования с применением метода конечных элементов. Результаты. Разработана методика диагностики состояния футеровки индукционной канальной печи для плавки бескислородной меди, которая позволяет определять дислокацию и размер протеканий жидкого металла путем анализа распределения температуры по поверхности корпуса индуктора и печи. Научная новизна. Впервые установлена связь между распределением температурного поля на поверхности корпуса печи и дислокацией и размерами протеканий жидкого металла в ее футеровке. Практическое значение. Использование предложенной методики позволит проводить более точную диагностику состояния футеровки индукционных канальных печей, а также определять расположение и размеры протеканий жидкого металла, создавая основы для прогнозирования ресурса работы печи en Інститут технічних проблем магнетизму НАН України Електротехніка і електромеханіка Електротехнічні комплекси та системи. Силова електроніка Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture Article published earlier |
| spellingShingle | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture Zolotaryov, V.M. Shcherba, M.A. Belyanin, R.V. Mygushchenko, R.P. Kropachek, O.Yu. Електротехнічні комплекси та системи. Силова електроніка |
| title | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| title_full | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| title_fullStr | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| title_full_unstemmed | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| title_short | Comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| title_sort | comparative analysis of electrical and thermal control of the lining state of induction apparatus of copper wire manufacture |
| topic | Електротехнічні комплекси та системи. Силова електроніка |
| topic_facet | Електротехнічні комплекси та системи. Силова електроніка |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/147634 |
| work_keys_str_mv | AT zolotaryovvm comparativeanalysisofelectricalandthermalcontroloftheliningstateofinductionapparatusofcopperwiremanufacture AT shcherbama comparativeanalysisofelectricalandthermalcontroloftheliningstateofinductionapparatusofcopperwiremanufacture AT belyaninrv comparativeanalysisofelectricalandthermalcontroloftheliningstateofinductionapparatusofcopperwiremanufacture AT mygushchenkorp comparativeanalysisofelectricalandthermalcontroloftheliningstateofinductionapparatusofcopperwiremanufacture AT kropachekoyu comparativeanalysisofelectricalandthermalcontroloftheliningstateofinductionapparatusofcopperwiremanufacture |