USING DIGITAL MONITORING SYSTEMS TO IMPROVE ENERGY EFFICIENCY OF INDUCTION HEATING
DOI:
https://doi.org/10.35546/kntu2078-4481.2025.4.1.17Keywords:
induction furnaces, digital monitoring systems, power supply instability, digitalization of productionAbstract
The article considers scientific and practical aspects of increasing the energy efficiency of technological lines with induction furnaces by implementing modern digital monitoring and control systems. In the context of increasing requirements for the stability and efficiency of metallurgical production, the issue of minimizing energy losses arising from power supply instability is of particular relevance. The paper analyzes in detail the impact of voltage fluctuations, harmonic distortions, phase asymmetry, and short-term sags/surges on the processes of induction heating of metals. It is shown that these factors lead to a decrease in the efficiency of induction installations, instability of temperature regimes, deterioration of the homogeneity and purity of the melt, as well as an increase in specific electricity consumption. The feasibility of using modern digital technologies is substantiated, including industrial data acquisition sensor systems, microprocessor controllers, cloud analytics platforms, and industrial communication protocols. Their implementation allows for continuous monitoring of power supply parameters, currents, temperatures, frequency and active/reactive power in real time, as well as timely recording of deviations from optimal operating modes of induction systems. Implementation of digital filtering, forecasting and adaptive control algorithms helps to increase the stability of the melting process and allows to automatically compensate for external power grid influences. Particular attention is paid to the integration of digital monitoring systems into the multi-level structure of enterprise management. This creates the basis for the development of "smart production" in the metallurgical industry, where data from equipment is used to promptly optimize production processes, increase equipment reliability and reduce energy costs. The results of an experimental study on the basis of a metallurgical enterprise are presented, which demonstrate an increase in energy efficiency of a technological line with induction furnaces by 12-15% after the implementation of an intelligent monitoring system. In addition to saving electricity, improved temperature stability, reduced downtime and increased predictability of the technical condition of the equipment were recorded. Thus, the implementation of digital monitoring systems contributes not only to increasing the efficiency of energy resources use, but also ensures increased reliability and predictability of technological processes in metallurgy under conditions of unstable power supply. The results obtained can be used as a scientific basis for further development of methods for energy optimization, digitalization and automation of production processes in industrial enterprises.
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