Induction heating equipment is a kind of areas that many people have to know more about. We need to know when and the best way to apply this technology, if it is the appropriate one for the job and learn how to buy it if we have to do so. Let’s be taught more.
Power Supply
Power, expressed in kilowatts (kW), refers back to the induction energy-supply size. An influence provide have to be sized to heat a given mass or given surface space to a selected temperature within a specified time. A general rule of thumb is that the surface area (uncovered to the coil) used to find out the ability level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the ability density (kW/inch2) required. For instance, a quench-and-tempered microstructure is optimum for most induction applications.
More energy shouldn’t be necessarily better. Matching the ability and frequency is the key. While more energy permits you to heat faster, it might also melt the surface or produce a deeper pattern (there is additionally more danger of by hardening), and it is harder to manage grain growth.
Frequency
High frequency in the form of alternating present is passed through the coil to create a magnetic area producing eddy currents. These are generated within the metal under the surface, and the resistance to this current flow is the principal supply for heating of the metal.
The following guideline for «relative» depth of penetration (depth of hardening or case depth) as a operate of frequency may be useful. This information is application-specific and dependent on both energy density and heat time but is considered typical of what is found within the industry:
@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch
@ one hundred kHz the case depth developed is (approximately): 0.050-0.080 inch
@ 30 kHz the case depth developed is (approximately): 0.080-0.a hundred and twenty inch
@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch
The depth of present penetration (hardened depth) is a function of part diameter and the resistivity of the material. There is an optimum depth of current penetration range, which is what each manufacturer strives to provide.
Higher frequency has a definite advantage when you’ve marginal prior part microstructures (annealed or normalized). Higher frequency permits the concentration of more energy close to the surface of the part, avoiding long heating instances or necessities for higher energy density (more costly when it comes to $/kW).
Tuning
Tuning (power-provide load matching) is an important consideration to achieve the desired case-depth profiles and for total energy-system efficiency. This is completed by adjusting the faucet of a variable-ratio transformer or by adding/subtracting a portion of a capacitor to achieve the desired frequency and a balanced load match between amperes, volts and kW. These are typically viewed on a meter panel on the ability supply.
The goal is to have a system that requires a minimal quantity of tuning, which turns into more necessary as energy levels approach the utmost nameplate ranking of the facility supply. For consistency of heating, the ability supply needs to be tuned so that it shouldn’t be running to its limit.
Computer-managed and recipe-selected automatic capacitor contactors can be used to load match when many alternative workpiece sizes are heat handled on the identical piece of equipment. Many energy-provide producers design a tuning window that allows you to make some changes to the part measurement being run. When only one part is dedicated to a system, no tuning is required after initial setup and testing.
Coils
All workitems have their own perform, form and properties. Coils (inductors) are water-cooled copper tubing or machined from stable copper blocks. They are designed and constructed specifically to satisfy the metallurgical requirements and production rates of the workpiece. Coils require periodic maintenance (repair) and must be suitable for the applications whether it be scanning, static heating or single-shot heating.
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