What Is the Electric Induction Melting Furnace?

The HLQ Electric Induction Melting Furnace with Electric Tilting Device
is a medium-frequency batch melting system comprising an induction power generator,
resonant compensation components and a crucible furnace arranged to pour molten
metal by controlled tilting. Instead of heating a crucible with fuel flames,
a water-cooled copper inductor generates an alternating magnetic field that
induces current in conductive metal or a compatible conductive crucible.
The DW-MF series is intended for suitably configured steel, stainless steel,
copper-alloy, aluminum and precious-metal batches. Electrical tilting can
simplify repetitive pouring, but actuator type, braking, tilt limits and
fully loaded performance must be specified separately for the actual supplied unit.

Product Overview

For additional furnace configurations, compare HLQ’s
induction melting furnaces with tilting devices.

Key Applications

Electric induction melting furnaces are suitable for controlled batch
melting operations in foundries, casting workshops, metal recycling facilities
and specialized alloy production.

Electric Tilting vs. Hydraulic Tilting

Suitable Materials

Material properties determine the required melting temperature,
heating energy, crucible selection and operating conditions.

Crucible Selection Guide

For larger copper melting applications, explore
copper induction melting furnace designs.

Working Principle

The electric induction melting furnace uses electromagnetic induction
to generate heat in conductive metal.

The induction generator supplies medium-frequency alternating current
to a water-cooled copper coil. The resulting alternating magnetic field
induces eddy currents in the charge or a compatible conductive crucible.
Electrical resistance converts these currents into heat.

When the metal reaches the required temperature and composition,
the electric tilting device allows controlled pouring into a suitable
ladle or mold.

Figure 1. Working Principle Diagram

      THREE-PHASE AC INPUT
               |
               v
    +----------------------+
    | DW-MF GENERATOR      |
    +----------------------+
               |
               v
    +----------------------+
    | CAPACITOR / MATCHING |
    +----------------------+
               |
               v
    +----------------------+
    | INDUCTION COIL       |
    | WATER COOLED         |
    +----------------------+
               |
               v
     ALTERNATING MAGNETIC
             FIELD
               |
               v
    +----------------------+
    | METAL + CRUCIBLE     |
    | EDDY CURRENT HEATING |
    +----------------------+
               |
               v
       MELTING COMPLETED
               |
               v
       TEMPERATURE CHECK
               |
               v
       ELECTRIC TILTING
               |
               v
        CONTROLLED POUR

Operating Stages

Technical Specifications

The following specifications are based on the published DW-MF series
information. Where the original product page does not provide a verified
parameter, confirmation is required before final equipment selection.

DW-MF Power Comparison

The original source does not clearly establish whether the listed weights
refer to the generator cabinets or complete furnace assemblies.

Published Melting Capacity

These figures are published batch-capacity references, not guaranteed
hourly melting production. Alternative quantities may require different
crucibles or furnace configurations.

Recommended Model Selection

An induction melting furnace should be selected according to the actual
metal charge, crucible capacity, target temperature and production cycle.

Additional Selection Criteria

Process Workflow

  CHECK METAL GRADE
          |
          v
  INSPECT CHARGE DRYNESS
          |
          v
  CHECK CRUCIBLE AND COOLING
          |
          v
  LOAD METAL CHARGE
          |
          v
  START INDUCTION MELTING
          |
          v
  CHECK TEMPERATURE AND CHEMISTRY
          |
          v
  PREPARE DRY LADLE
          |
          v
  ACTIVATE ELECTRIC TILTING
          |
          v
  POUR MOLTEN METAL
          |
          v
  RETURN FURNACE TO HOME POSITION
          |
          v
  RECORD ENERGY AND PRODUCTION

Process Inspection Requirements

Coil and Fixture Design

The induction coil, crucible and electric tilting system must be
designed as an integrated electromagnetic and mechanical assembly.

Design Parameters

Electric Tilting Mechanism Inspection

Cooling Water Calculation

For water near ordinary industrial temperatures:

Cooling Load (kW) = 1.163 × Flow (m³/h) × Temperature Rise (°C)

These are illustrative calculations, not confirmed DW-MF cooling
requirements. The actual cooling system should be selected from
measured heat rejection and manufacturer-specified water conditions.

For related generator configurations, see HLQ’s
medium-frequency induction heating power supply systems.

Control System and Automation

The original page does not specify a complete PLC control architecture,
tilting-drive interface or automatic pouring system.

The following functions are recommended engineering features that
should be confirmed for the selected model.

Recommended Production KPIs

Common Problems and Solutions

Engineering Selection Guide

1. Calculate Electrical Energy Required for Melting

The electrical energy required for batch melting depends on the
material, initial temperature, melting point, superheat and
overall system losses.

Electrical Energy (kWh) = Charge Weight (tonnes) × Specific Consumption (kWh/t)

Illustrative Melting Energy Planning

These values are preliminary planning assumptions and are not
independently verified DW-MF performance data.

2. Estimate Melting Time

Estimated Energized Time (min) =
60 × Electrical Energy (kWh) / Average Real Input Power (kW)

The table is based on hypothetical energy consumption and average
electrical input. It does not represent tested heating times or
guaranteed production output.

Figure 3. Melting Time vs. Average Electrical Power

ASSUMED 100kg STEEL BATCH
TOTAL ELECTRICAL ENERGY: 80kWh

AVERAGE POWER       ENERGIZED TIME

80kW    ########################   60min

100kW   ###################        48min

120kW   ################           40min

160kW   ############               30min

Illustrative calculation only.

3. Calculate Actual Production Capacity

Gross Production (kg/h) =
60 × Batch Weight (kg) / Tap-to-Tap Time (min)

Actual saleable production also depends on metal yield,
slag losses, casting acceptance and equipment downtime.

4. Calculate Three-Phase Electrical Requirements

For balanced three-phase electrical supply:

Apparent Power (kVA) = 1.732 × Voltage (V) × Current (A) / 1000

Real Power (kW) = Apparent Power (kVA) × Power Factor

These calculations assume a power factor of 0.90.
The actual electrical design should use measured or certified
equipment data, including harmonic and transformer requirements.

5. Electric Tilting System Selection

6. Factory Acceptance Testing

Advantages

Limitations

Why Choose HLQ Induction Equipment?

HLQ Induction Equipment Co., Ltd. supplies medium-frequency induction
heating generators and metal melting equipment for industrial applications.

For an electric tilting furnace project, the correct solution must
combine suitable electrical power, a matched induction coil, a compatible
crucible, reliable cooling and a properly designed tilting mechanism.

Customers should request complete technical specifications and
factory acceptance results based on their actual metal and required
production capacity.

Information Required for Quotation

For larger ferrous foundries, explore HLQ
industrial induction furnaces for steel and cast iron melting.

For precious-metal applications, compare
induction gold melting furnace systems.

Core FAQs

FAQ 1. What is an electric induction melting furnace?

An electric induction melting furnace is a system that melts conductive
metal using electromagnetic induction. Alternating current in an induction
coil creates a magnetic field that induces electrical currents and
heat within the charge or a suitable conductive crucible.

FAQ 2. What is the purpose of an electric tilting device?

The electric tilting device moves the furnace into a controlled pouring
position. Its mechanical design must provide adequate load capacity,
travel limits, braking and safe handling of molten metal.

FAQ 3. Which DW-MF models are available?

The published DW-MF series includes eight models:
DW-MF-15, DW-MF-25, DW-MF-35, DW-MF-45, DW-MF-70,
DW-MF-90, DW-MF-110 and DW-MF-160.
Their maximum listed input powers range from 15kW to 160kW.

FAQ 4. How much steel can DW-MF-160 melt?

The published capacity table lists 100kg of steel or stainless steel
for the DW-MF-160 configuration. This is a batch-capacity reference
rather than a guaranteed hourly melting rate.

FAQ 5. How long does one batch take to melt?

The original product page describes approximately 30–50 minutes for
an initial cold furnace and 20–30 minutes for subsequent hot-furnace
melts. The actual time depends on charge mass, material, crucible,
temperature and sustained electrical power.

FAQ 6. What cooling system is required?

The cooling system must provide adequate water flow, pressure and
temperature control for the generator, induction coil and other
water-cooled components. Cooling equipment should be selected from
the actual heat load and manufacturer’s requirements.

FAQ 7. Can one electric induction furnace melt different metals?

Different metals may be melted using suitably configured induction
furnaces, but the same crucible, lining and process settings should
not automatically be used for all alloys.
Material compatibility and operating temperature must be verified.

FAQ 8. How should an electric induction melting furnace be selected?

Select the furnace according to the metal grade, batch weight,
target melting temperature, production rate, available electricity,
cooling conditions and pouring requirements.
The final selection should be validated through a factory acceptance
test using representative material.

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