Suggestions For Deciding On Induction Heating Equipment

Suggestions For Deciding On Induction Heating Equipment

Induction heating equipment is a type of areas that many of us have to know more about. We have to know when and tips on how to apply this technology, if it is the precise one for the job and how to buy it if we have to do so. Let’s learn more.

Power Supply
Power, expressed in kilowatts (kW), refers to the induction energy-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 (exposed to the coil) used to determine the facility level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will influence the power density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for many induction applications.

More power is not necessarily better. Matching the power and frequency is the key. While more power helps you to heat faster, it may additionally soften the surface or produce a deeper sample (there is also more danger of by means of hardening), and it is harder to control grain growth.

Frequency
High frequency in the form of alternating current is passed by way of the coil to create a magnetic field 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 operate of frequency is likely to be useful. This information is application-particular and depending on both energy density and heat time however is considered typical of what's 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): 0.080-0.120 inch
@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch
The depth of present penetration (hardened depth) is a perform 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 distinct advantage when you have marginal prior part microstructures (annealed or normalized). Higher frequency allows the focus of more energy close to the surface of the part, avoiding lengthy heating occasions or necessities for higher energy density (more costly when it comes to $/kW).

Tuning
Tuning (power-supply load matching) is a very important consideration to achieve the desired case-depth profiles and for general 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 ability supply.

The goal is to have a system that requires a minimal quantity of tuning, which turns into more essential as energy levels approach the maximum nameplate ranking of the power supply. For consistency of heating, the facility provide must be tuned so that it just isn't running to its limit.

Computer-controlled and recipe-selected automated capacitor contactors can be utilized to load match when many different workpiece sizes are heat treated on the same piece of equipment. Many power-provide manufacturers design a tuning window that permits you to 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, form and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They are designed and built specifically to satisfy the metallurgical necessities and production rates of the workpiece. Coils require periodic upkeep (repair) and must be suitable for the applications whether or not it be scanning, static heating or single-shot heating.

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