Induction heating equipment is a kind of areas that many of us have to know more about. We have to know when and find out how to apply this technology, if it is the right one for the job and easy methods to purchase it if we need to do so. Let’s learn more.
Power Supply
Power, expressed in kilowatts (kW), refers back to the induction energy-provide size. A power supply should be sized to heat a given mass or given surface space to a selected temperature within a specified time. A common rule of thumb is that the surface space (exposed to the coil) used to determine the ability level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the facility density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for most induction applications.
More energy isn’t necessarily better. Matching the ability and frequency is the key. While more energy helps you to heat faster, it may melt the surface or produce a deeper pattern (there may be additionally more hazard of by means of hardening), and it is harder to manage grain growth.
Frequency
High frequency in the form of alternating current is passed by the coil to create a magnetic field producing eddy currents. These are generated within the metal under the surface, and the resistance to this present flow is the principal source for heating of the metal.
The next guideline for «relative» depth of penetration (depth of hardening or case depth) as a operate of frequency could 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 business:
@ 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.one hundred twenty inch
@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch
The depth of current penetration (hardened depth) is a function of part diameter and the resistivity of the material. There’s an optimum depth of current penetration range, which is what every producer strives to provide.
Higher frequency has a distinct advantage when you have marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy near the surface of the part, avoiding long heating times or necessities for higher energy density (more costly in terms of $/kW).
Tuning
Tuning (power-supply load matching) is a vital consideration to achieve the desired case-depth profiles and for overall power-system efficiency. This is finished by adjusting the tap 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 considered on a meter panel on the power supply.
The goal is to have a system that requires a minimal quantity of tuning, which becomes more essential as energy levels approach the maximum nameplate rating of the ability supply. For consistency of heating, the ability provide ought to be tuned so that it will not be running to its limit.
Computer-controlled and recipe-chosen automatic capacitor contactors can be used to load match when many different workpiece sizes are heat treated on the same piece of equipment. Many power-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 workpieces have their own operate, form and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They’re designed and built specifically to fulfill the metallurgical necessities and production rates of the workpiece. Coils require periodic upkeep (repair) and must be suitable for the applications whether it be scanning, static heating or single-shot heating.
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