感应加热式热处理设备,是利用电磁感应产生涡流电发热现象,对工件表面加热进行热处理。由于其生产效率高,能耗低以及容易实现自动化生产、污染较少也较安全等优点,应用日趋广泛。按设备产生交变电磁场的频率高低,可将其分为高频、中频和工频三类(高频频率为30~500KHz;中频频率为1~10 KHz;工频频率为50Hz的工业交流电)。感应加热设备使用的电源电压为220~380V,但有的设备内部电压高达10kV以上。故使用感应加热热处理设备时,必须注意高压电的用电安全和电磁波辐射污染的问题。
高频感应加热设备的安全操作
高频感应加热设备主要为电子(真空)管,产生高频电磁振荡,电功率为10~200kW,机内最高电压约为15kV。因此,要求设备内绝缘性能必须良好,机壳等有关部分必须可靠接地。操作工位应放置绝缘橡胶垫。设备旁应设有防护木栏杆,涂红白相间的油漆。挂高压电危险标志。高频间应光线明亮、通风良好,室内温度应控制在15~35℃。安装排风装置,以排除工件加热时所散发的油烟废气。由于高频设备的频率为30~500 KHz,会产生射频幅射。当人体吸收一定辐射量后,会发生生物学变化,生物学变化随波长减短(频率增高)而增加表现为神经衰弱症候群和植物神经系统功能紊乱。因此对设备的辐射场源(如高频变压器、馈电线、工作电容、耦合电容及感应器等),应采取屏蔽措施。为防止电磁波外漏而影响附近(约100m内)的电子设备和无线电通讯,还应将全室屏蔽,要保证工作环境的辐射强度在规定范围以内(电场强度E≤20V/m;磁场强度H≤5A/m。操作时应注意:
(1) 必须有两人以上方可操作高频设备,并指定操作负责人。穿戴好绝缘鞋、绝缘手套和其它规定的防护用品。
(2) 操作者必须熟悉高频设备的操作规程,开机前应检查设备冷却系统是否正常,正常后方可送电,并严格按操作规程进行操作。
(3) 工作前应关好全部机门,机门应装电气联锁装置,保证机门未关前不能送电。高压合上后,不得随意到机后活动,严禁打开机门。
(4) 工件应去除毛刺、铁屑和油污,否则在加热时容易与感应器产生打弧现象。打弧现产生的电弧光既会损伤视力,也容易打坏感应器和损坏设备。
(5) 高频设备应保持清洁、干燥和无尘土,工作中发现异常现象,首先应切断高压电,再检查排除故障。
必须有专人检修高频设备,打开机门后,首先用电棒对阳极、栅极、电容器等放电,然后再开始检修,严禁带电抢修。
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