Induction heating equipment is one of those areas that many people must know more about. We need to know when and find out how 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 study more.
Power Supply
Power, expressed in kilowatts (kW), refers to the induction energy-supply size. A power provide should be sized to heat a given mass or given surface area to a selected temperature within a specified time. A basic rule of thumb is that the surface area (exposed to the coil) used to determine the power level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will influence the ability density (kW/inch2) required. For instance, a quench-and-tempered microstructure is optimum for most induction applications.
More power is just not necessarily better. Matching the power and frequency is the key. While more power allows you to heat faster, it may additionally melt the surface or produce a deeper sample (there is additionally more hazard of by hardening), and it is harder to control grain growth.
Frequency
High frequency in the form of alternating current is passed by means of the coil to create a magnetic discipline producing eddy currents. These are generated within the metal under the surface, and the resistance to this current flow is the principal source for heating of the metal.
The following guideline for «relative» depth of penetration (depth of hardening or case depth) as a function of frequency might be useful. This information is application-specific and dependent on both energy density and heat time however is considered typical of what’s found within the trade:
@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch
@ a 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 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 will have marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy near the surface of the part, avoiding lengthy heating instances or necessities for higher energy density (more costly by way of $/kW).
Tuning
Tuning (energy-provide load matching) is a very important consideration to achieve the desired case-depth profiles and for overall energy-system efficiency. This is done 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 considered on a meter panel on the facility supply.
The goal is to have a system that requires a minimal quantity of tuning, which turns into more important as energy levels approach the maximum nameplate ranking of the facility supply. For consistency of heating, the ability provide needs to be tuned in order that it shouldn’t be running to its limit.
Computer-managed and recipe-chosen automatic capacitor contactors can be used to load match when many different workpiece sizes are heat handled on the identical piece of equipment. Many energy-provide manufacturers design a tuning window that means that you can make some modifications to the part size 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 perform, form and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They’re designed and constructed specifically to satisfy the metallurgical requirements and production rates of the workpiece. Coils require periodic upkeep (repair) and have to be suitable for the applications whether it be scanning, static heating or single-shot heating.
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