Abstract: Disclosed is an electromagnet design that can be quickly disassembled, repaired, and reassemble. In one embodiment the electromagnet comprises a housing having a housing cavity. Carved or molded into the housing is a pair of opposing slots. An electromagnetic core comprising a ferromagnetic material wrapped with electrical wire is disposed within the housing cavity. A pair of braces are lodged within the slots in the housing cavity such that they overlap the electromagnetic core. A center shoe engages the braces and is secured to the housing by six bolts. The slots, braces, and center shoe design cooperate to secure the electromagnetic core within the housing cavity.

Abstract: A heating module for use in steel processing is provided. The module includes one or more gas heating zones and one or more induction heating coils intermixed among the gas heating zones. The modules are used to heat steel slabs to a consistent temperature throughout. Generally, the induction coils are used to increase the temperature of the slab, while the gas heating zones function to hold the slab at the increases temperature and to allow the heat to soak into the interior of the slab. The gas heating zones are generally lined with refractory material and include sufficient rollers to carry the steel slabs through the heating modules. The rollers are positioned in such a manner that the majority of the surface area of the roller is not within the interior of the gas heating zone at any one time. At least a segment of the floor of the gas heating zone is pivotable such that debris can be easily removed from the heating zone and such that the interior of the heating zone is easily accessed.

Abstract: Disclosed is a heating system for heating metal products in an oscillating induction furnace and a method of operation of the heating system. The heating system includes an oscillating induction furnace that in turn comprises a plurality of induction coils interspersed with a plurality of rollers. The metal products are oscillated within the induction coils on the plurality of rollers until heated to a target temperature. A logic device determines the power to be supplied to the induction coils, the number and speed of oscillation passes to conduct, the duration of time to be spent in the oscillating induction furnace, and the loading arrangement of the metal products within the oscillating induction furnace if two or more metal products are to be heated together in the oscillating induction furnace. The power supplied to the initial and final induction coils is metered by the logic device according to the proximity of the metal product to the initial and final induction coils.

Abstract: Methods and apparatus for securing induction coils within an induction coil module including a plurality of flexible connectors having a first end, a second end, and a length disposed between the first and second ends. A first attachment member is securely attached to the first end of the flexible connector and pivotably connected to a support assembly. A second attachment member is securely attached to the second end of the flexible connector 16. The second attachment member having an induction coil attached thereto. Correspondingly, the pivotal engagement of the flexible connectors in relation to the support assembly of the induction coil module facilitates a means for allowing the flexible connectors and their attached induction coils to move both horizontally and vertically in relation to the support assembly, thus dramatically reducing the potential for structural fatigue and stress fracturing of the various mechanical connections of an induction furnace.

Abstract: A shape meter for measuring the deviation from flatness of a moving rolled steel plate is disclosed. The shape meter includes a laser source for generating an illuminated spot on the steel plate. The laser spot must be separable or distinguishable from background radiation emitted by the steel plate. For instance, if the steel plate is hot and the laser source is an argon laser generating blue green light, the optical filter must pass the blue green light and filter the red thermal emissions. The laser light is directed onto the moving steel plate, and a detector measures the light scattered from the steel plate. The detector includes an optical filter, an optical lens, and a lateral effect diode sensor. A computer then calculates and reports the deviation from flatness of the moving rolled steel plate based on the scattered light measured with the lateral effect diode sensor.