Vibratory Furnace Charger

Vibratory Furnace Charger

A Vibratory Furnace Charger is an efficient system designed for the automatic feeding of metal charge materials into melting furnaces such as induction furnaces, cupolas, or electric arc furnaces. These chargers enhance safety and productivity in foundries and metal processing industries by minimizing manual handling and ensuring consistent feeding.

Vibrating Furnace Chargers are effective solutions to problems such as high labour cost, hazards to furnace operators faced in foundries, melting shops etc. Such a kind of automation allows foundry men to work at a safe distance thus preventing injures arising out of molten metal splash. It also facilitates in rapid and quick charging of the furnace thereby allowing maximum utilization of the furnace. In addition to this, the damage to furnace lining is avoided which normally occurs in manual charging of the furnaces.

Principle Of Operation of Vibrating Furnace Charger :

The required amount of scrap metal is loaded into the storage hoper at the loading point. The trolley carries the vibrating feeder along with the storage hopper to the furnace charging point. Here, the vibrating feeder is energized, and the material is effectively discharged into the furnace as per the required capacity. As the metal is melted down, fresh batch of metal can be fed into the furnace thereby keeping the furnace full. The capacity of the vibrating feeder can be varied by varying the amplitude of variations. The amplitude of vibrations can be varied by adjusting the position of centrifugal weights or by using a variable frequency drive (optional). A control panel specially designed to suit individual client requirement depending on the sequence of operations required is provided.

Components used in Vibratory Furnace Charger :

A Vibratory Furnace Charger consists of several essential components that work together to efficiently and safely charge the furnace with metal or scrap materials.

Key components used in a typical vibratory furnace charger system :

• Vibratory Feeder Tray : Made from heat-resistant steel or alloy. Conveys material from the hopper to the furnace. Vibrates to move the charge uniformly.
• Vibratory Drive Unit : Usually powered by an unbalanced motor or electromagnetic coil. Provides controlled vibration to the feeder tray.
• Storage Hopper / Bin : Holds a predetermined quantity of charge material. Feeds material into the vibrating tray in a controlled manner.
• Charging Car / Trolley : Mounted on rails or wheels. Moves the entire assembly (feeder + hopper) to and from the furnace. Often powered by electric motors.
• Control Panel : Manages the operations including vibration intensity, travel movement, timing, and safety interlocks. Typically includes VFDs, timers, and logic control (PLC-based in modern systems).
• Structure Frame / Base Frame : Rigid support for mounting all the other components. Designed to with stand vibration and furnace heat.
• Travel Mechanism : Includes motors, gearboxes, rails, and wheels. Allows the system to move to the furnace mouth and back.
• Heat Shields / Thermal Insulation : Protects the equipment and components from high furnace temperatures. It is usually found around the tray and front sections.
• Limit Switches / Sensors : Ensures position control of the charger and provides feedback for automation and safety.
• Cable Drag Chain / Conduit : Protects electrical wiring and pneumatic hoses during the trolley's movement.

Applications industries for Vibrating Furnace Charger :

Vibrating Furnace Chargers are widely used in various industries where bulk material needs to be loaded into furnaces in a controlled, efficient, and safe manner.

Below are the key application industries:

• Steel Plants
• Foundries
• Non-Ferrous Metal Processing
• Recycling Units
• Induction Furnace Charging
• Recycling Plants
• Heavy Engineering Industry
• Glass Manufacturing
• Metal Industries