Induction heating equipment is a kind of areas that many people have to know more about. We have to know when and the right way to apply this technology, if it is the proper one for the job and the best way to buy it if we need to do so. Let’s be taught more.
Power Supply
Power, expressed in kilowatts (kW), refers to the induction power-provide size. An influence supply should be sized to heat a given mass or given surface area to a selected temperature within a specified time. A general rule of thumb is that the surface area (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 example, a quench-and-tempered microstructure is optimum for many induction applications.
More power isn’t essentially better. Matching the facility and frequency is the key. While more energy permits you to heat faster, it may soften 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 current is passed through the coil to create a magnetic subject 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-particular and dependent on each energy density and heat time but is considered typical of what’s found within the trade:
@ 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): 0.080-0.120 inch
@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch
The depth of current penetration (hardened depth) is a perform of part diameter and the resistivity of the material. There may be an optimum depth of present penetration range, which is what every manufacturer strives to provide.
Higher frequency has a definite advantage when you will have marginal prior part microstructures (annealed or normalized). Higher frequency allows the focus of more energy near the surface of the part, avoiding long heating instances or necessities for higher power density (more costly in terms of $/kW).
Tuning
Tuning (energy-provide load matching) is a very important consideration to achieve the desired case-depth profiles and for general power-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 power supply.
The goal is to have a system that requires a minimal amount of tuning, which turns into more vital as energy levels approach the utmost nameplate ranking of the ability supply. For consistency of heating, the power provide ought to be tuned in order that it is not running to its limit.
Computer-managed and recipe-selected automatic capacitor contactors can be utilized to load match when many different workpiece sizes are heat handled on the identical piece of equipment. Many power-provide manufacturers design a tuning window that means that you can make some adjustments 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 function, shape 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 should be suitable for the applications whether it be scanning, static heating or single-shot heating.
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