Induction heating equipment is a type of areas that many people have to know more about. We need to know when and how one can apply this technology, if it is the fitting one for the job and the right way to buy it if we need to do so. Let’s learn more.
Power Supply
Power, expressed in kilowatts (kW), refers to the induction power-supply size. A power supply must be sized to heat a given mass or given surface area to a specific temperature within a specified time. A general rule of thumb is that the surface space (uncovered to the coil) used to determine the facility level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the power density (kW/inch2) required. For instance, a quench-and-tempered microstructure is optimum for most induction applications.
More power shouldn’t be essentially better. Matching the facility and frequency is the key. While more energy permits you to heat faster, it may additionally melt the surface or produce a deeper pattern (there may be additionally more hazard of by way of hardening), and it is harder to control grain growth.
Frequency
High frequency within the form of alternating present is passed by the coil to create a magnetic discipline 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 function of frequency is likely to be useful. This information is application-specific and depending on both power density and heat time however is considered typical of what is discovered 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): 0.080-0.120 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 is an optimum depth of present penetration range, which is what every producer strives to provide.
Higher frequency has a definite advantage when you may have marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy close to the surface of the part, avoiding long heating instances or necessities for higher power density (more costly in terms of $/kW).
Tuning
Tuning (power-supply load matching) is a very important consideration to achieve the desired case-depth profiles and for overall power-system efficiency. This is finished 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 power supply.
The goal is to have a system that requires a minimal amount of tuning, which becomes more essential as power levels approach the utmost nameplate rating of the ability supply. For consistency of heating, the facility supply must be tuned so that it is just not running to its limit.
Computer-managed and recipe-chosen 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 means that you can make some changes to the part dimension 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, shape and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They are designed and built specifically to meet the metallurgical requirements and production rates of the workpiece. Coils require periodic maintenance (repair) and should be suitable for the applications whether or not it be scanning, static heating or single-shot heating.
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