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1. A Training seminar on Induction
Furnace by Stead Fast Engineers Pvt.
Ltd.
http://www.steadfastengg.com/

2. COMPANY PROFILE
 Established in 1990, Stead Fast Engineers Pvt Ltd is an
engineering company engaged in designing and manufacturing of
Induction Melting furnaces, Induction Billet Heaters and
Refractory Lining Machines for Foundries, Steel Plants and
Forging units. With the help of years of experience and a highly
skilled team, we create products with attention to every minute
detail thereby making the products both user friendly and
economical.
 Stead Fast Engineers provides world class induction heating and
melting solutions for both ferrous and Non ferrous with a great
focus on customization so that every machine is nothing less
than perfect. With a family of more than 400 satisfied customers
all over the country and abroad, Stead Fast Engineers is
expanding at a rapid pace. With offices located in major cities we
ensure that the service is quick and effective and breakdown time
is negligible. Adopting stringent quality management systems
during different stages of production - the pre-process, In-process
and pre-dispatch stage we believe in manufacturing the best
quality every time.

3. INDUCTION HEATING/MELTING
●If an AC current is fed through a coil, the
electromagnetic field that is produced is constantly
changing. This changing magnetic field induces
electrical current (AC) in another circuit that is held
close .
●This induced secondary current can be utilized to
generate heat in the circuit of the second conductor
by exploring the electrical losses due to the current.
These losses are due to Hysterises and Eddy current.

4. BLOCK DIAGRAM
Input current
&
voltage
DC
Choke
Load
(Resistor)
Inverter
control
Converter
control
Convert
Pulse
Invert
Pulse
PANEL
SL Card, ITC Card, Burden Card, Relay Card
3 Ø Supply

5. ET- INDUCTION MELTING
FURNACE
● ET-Induction Melting Furnace constitute following part:
 Generator Panel
 DC Choke
 Coil Cradle Assembly
 De-Mineralise Water Circulation Unit
 Changeover Switch
 Hydraulic Unit

6. GENERATOR PANEL
●Generator Panel consist of following section:
 3-phase Bridge Rectifier with freewheel diode.
 (DC to AC) Inverter section
 Starting Circuit
 Control Electronic PCB Cards section
 Transformer for power supply

7. ● Incoming mains 3- supply from furnace
transformer is rectified by Full Control Bridge
Rectifier.
● Six identical Thyristor which are connected in Bridge
configuration to convert Incoming AC to
Corresponding DC. Six Thyristor stand for R+, R-,
Y+, Y-, B+ & B-.
3-phase Bridge Rectifier with
freewheel diode

8. (DC to AC) Inverter section
●The inverter is responsible for converting High
Voltage DC to AC to feed it to the load circuit . It
is a single phase bridge Parallel Inverter
●Thyristor are connected in four arms. Each arm
has serially stack thyristor in range of 3-4
depending of output Voltage designed. Thyristor
in diagonal pair are fired in each half cycle of
medium frequency , this frequency is determine
by parallel resonant LC circuit.

9. Starting Circuit
●Starting circuit plays major role for
reliable starting of furnace.
●It consist of Starting Card, Start
Capacitor, Start Choke, Start Thyristor
Module and Start Contactor unit.

10. ELECTRONIC CONTROL CARD
●This section consist of following PCB cards:
 ET-SL ( Sequence and Limit Control Card )
 ET-ITC ( Inverter Control Card )
 ET-TOV ( TOT Generation and Over voltage Detection)
 ET-PS (Power Supply)
 ET-SC ( Starting Card)
 ET-133/2 ( Converter Firing Pulse Generation Card)
 ET-133/3 (Amplification and Isolation Card)
 ET-77 ( Inverter Firing Amplification and Isolation)
 ET-84 ( Water Conductivity Measure )
 ET-125 ( Earth Leakage Detection)
 ET-BRDN ( Burden Board)
 ET-RLY ( Relay )

11. ET-SL

12. ET-ITC

13. ● Works on the principle of transformer, I.e primary and
secondary are linked by magnetic flux. Transformer is
a electro-magnetic device so here in DC , Choke acts
only as resistance , which is in microohms.
● DC chock converting pulsating DC to pure DC
● It prevent thyrister of inverter from large current
DC CHOKE

14. COIL CRADLE ASSEMBLY

15. FURNACE COIL
●It is made of high conductivity
●For maximum efficiency of coil a
space is maintain by the spacer.
●Additional stainless steel cooling
turn at the top and bottom is
clamped for providing uniform
cooling through out of the coil
cradel.

16. DEMINERALISE WATER
CIRCULATION UNIT
●DM water is deminrlised water.
●DM water has very less conductivity (less
then 10µ/semens.
●DM water is widely used for cooling purpose
of power equipments.
●As for example in the coil cradel, change over

17. CHANGE OVER SWITCH
●This is offload switch used to alternately connect two furnace
crucible with single power source.
●It can be operated manually or pneumatically. It is water cooled to
allow better heat dissipation.
●The contacts points of switch is made by silver for better contacts.
●The current carrying capacity is from 2KA to 20KA.

18. HYDRAULIC UNIT
● This is the tilting structure of furnace
● With the help of hydrolic unit we can tilt the furnace upto 95
● Tilting process is done with the help of oil pressure which is
created by motor
● The oil use for tilting is enklo-54 which has high viscous in
nature