Case Study: Mitigating Production Downtime Risks and Improving Productivity through the Upgrade of High-Frequency Induction Furnaces
The update of the existing induction furnace eliminates the risk of production stoppage due to obsolete parts and enhances customer value. The melting time is dramatically shortened, and productivity is improved by up to three times.
Case study of the introduction of a high-frequency induction furnace. In a certain foundry (iron and metal products), the existing high-frequency induction furnace had aged, increasing the risk of production stoppage due to obsolete parts. Therefore, by updating the high-frequency induction furnace, we avoided the risk of production stoppage caused by obsolete parts, dramatically reduced melting time, increased melting volume, and improved production efficiency through enhanced material production efficiency. We also achieved improvements in the working environment and safety.
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basic information
Related Product: High-Frequency Induction Furnace F-MELT100G https://www.fujielectric.co.jp/products/foundry_solution/solution_detail/solution_f-melt.html A high-frequency induction furnace that combines Fujie Electric's "power electronics technology," "high-voltage insulation technology," and "analysis technology." It features a high-efficiency furnace body that improves melting unit consumption and is equipped with a high-voltage IGBT stack. With over 2,500 units of high-frequency induction furnaces delivered, it promotes carbon neutrality in foundries and enhances productivity and stability based on proven results. The official website (https://www.fujielectric.co.jp/products/foundry_solution/) provides product information as well as case studies that help optimize operations, save energy, and support BCP for foundries. If accessing from a search engine, please search for "foundry solutions."
Applications/Examples of results
Case Study: Elimination of Production Downtime Risk and Improvement of Productivity through High-Frequency Induction Furnace Upgrade [Case Study Overview] - Industry: Foundry (Steel and Metal Products) - Introduced Product: High-Frequency Induction Furnace (F-MELT100G) [Customer Feedback] The risk of production downtime due to obsolete parts has been eliminated, allowing for secure operations. Additionally, the dramatic reduction in melting time has increased the melting volume, resulting in improved material production efficiency and enhanced customer value. In the equipment upgrade, the manufacturing innovation group and the manufacturing department worked together to focus on the following measures. [Challenges Before Implementation] - The existing high-frequency induction furnace was aging, posing a risk of production downtime due to obsolete parts. - The existing furnace operated with two furnaces and one power supply (switchable), which prevented simultaneous melting and holding/heating, leading to significant losses in melting time and power consumption. [Implementation Effects] - Improved working environment through the installation of dust collection hoods. - Flattened the workspace to enhance safety. - Added emergency power supply to the cooling water system to strengthen equipment protection during power outages. - Improved the workability of refractory dismantling (from manual to automated).
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High-frequency induction furnace F-MELT100G that realizes energy saving for electric furnaces.
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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
