Case study: Increased batch size of the melting furnace and introduction of a high-capacity, high-power IGBT power supply.
Increased the batch size of the melting furnace and introduced a high-power IGBT power supply, significantly improving production efficiency.
■High-frequency induction furnace that realizes energy saving for electric furnaces The high-frequency induction furnace F-MELT100G, which consolidates energy-saving and power supply technologies into a high-efficiency induction furnace, contributes to the energy saving of electric furnaces and the carbon neutrality of industrial furnaces. Additionally, utilizing IoT-based data analysis technology makes the induction furnace user-friendly, smartly analyzes data, feeds it back to the equipment, enables optimization of operations, reduces costs, and contributes to improved production efficiency.
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basic information
Case study of the introduction of a high-frequency induction furnace. The challenge faced by our customer in the casting factory (machinery) was that the batch capacity of the melting furnace was small for their main large casting products, leading to poor production efficiency as they were using multiple crucibles for casting. By introducing our high-frequency induction furnace and increasing the batch size of the melting furnace while implementing a high-power IGBT power supply*, we significantly improved production efficiency. *IGBT (Insulated Gate Bipolar Transistor) is a type of power semiconductor that can handle high voltage and large current, used for controlling and supplying power. It features reduced power loss and efficient heat dissipation.
Applications/Examples of results
■Overview of Implementation Case Casting Factory (Machinery) Implemented Product: High-Frequency Induction Furnace <Customer Feedback> This was our first time adopting a furnace from Fuji Electric. The introduction of case studies from other companies was very helpful during our equipment planning. We also understood the usability of this furnace through visits to other users, and the introduction of surrounding equipment manufacturers served as a reference for our selection. Before implementation, the large casting process took from early morning until night, but after implementation, we were able to complete it within the scheduled time. <Issues Before Implementation> The batch capacity of the melting furnace was small for our main large casting products, and we were using multiple crucibles for casting, which resulted in poor production efficiency. <Implementation Effects> By increasing the batch size of the melting furnace and introducing a high-power IGBT power supply, we significantly improved production efficiency.
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Improving production efficiency and avoiding production stoppage risks with the introduction of IGBT power supply.
Visualization of operations in the new factory using the furnace monitoring system.
High-frequency induction furnace F-MELT100G that realizes energy saving for electric furnaces.
Examples of energy saving and CO2 reduction through the transition to electric high-frequency induction furnaces.
Increased the batch size of the dissolution furnace and introduced a high-power IGBT power supply.
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Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
