Precise Temperature Control for Molten Ferrous Alloy in Induction Furnace

A precise control system for a molten ferrous alloy temperature above 1700 K after the completion of induction melting has been developed in order to produce high quality casting parts for automobiles. In this system, the molten ferrous alloy temperature is measured just one time by a disposable thermocouple after the melting. The system predicts the temperature transition after the measurement using an original thermal model, and adjusts the supplied electric power to the furnace automatically according to the predicted temperature.

Using this thermal model, the system has attained control deviations within ±5K under the following temperature controls, and contributed to the quality control of casting parts and the energy-saving during furnace operations.

• Casting temperature for a cast-steel of 1813 K in a 300 kg capacity high-frequency induction furnace on the “Toyota Vacuum Casting Process”.
• Tapping temperature for a cast-iron of 1723 K in a 18000 kg capacity medium-frequency induction furnace in Toyota foundry.