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Considerations When Selecting an Induction Heating System

 

Induction heating provides many benefits to manufacturing processes because it is a speedy, energy-efficient, flameless method of heating electrically conductive materials. A typical system includes an induction energy provide, workhead with a copper coil and a chiller or cooling system. Present flows by way of the coil to create an electromagnetic alternating field. When a conductive part is placed inside the coil, current is induced to run through it. Present flow combined with the resistance properties of the conductive part leads to heat generation.

 

 

It's critical to select the fitting system to your application and its requirements. An overpowered system may imply you will spend more than you want to, while an underpowered system may lengthen your heating process and sluggish down production. Listed here are 10 factors to consider when deciding on an induction heating system.

 

 

1. Your Part’s Materials

 

Induction directly heats conductive materials equivalent to metals. Nonconductive materials are generally heated with a conductive susceptor. Resulting from hysteresis, magnetic materials are heated more simply than nonmagnetic supplies; consequently, nonmagnetic materials typically require more power. Metals with high resistivity like steel heat quickly, while low-resistivity metals like copper or aluminum require more heating time.

 

 

2. Depth of Heating Penetration

 

The induced present will be most intense on the surface of your part. In truth, more than eighty% of the heat produced in the part is produced on the "skin," or surface. Consequently, larger parts and parts that require by-heating take more time to heat than those which might be thin or small.

 

 

3. Working Frequency

 

Lower-frequency, higher-energy systems are generally suited for heating bigger parts that require through heating. Lower-power, higher-frequency systems are often the suitable alternative for surface heating. As a general rule, the higher the frequency, the shallower the heating of the part.

 

 

4. Utilized Power

 

The output power of your induction heating power provide determines the relative speed at which your part is heated. The mass of the part, rise in temperature and heat losses from convection and conduction need to be considered. Often, the induction equipment manufacturer can help you make this assessment.

 

 

5. Rise in Temperature Required

 

Induction can generate a significant change in temperature, but, typically speaking, more energy is needed to accommodate a significant temperature change and will impact your energy-provide choice. The rate of temperature change also affects your power-provide choice. The faster the rate of change, the more significant the facility requirement.

 

 

6. Coil Design

 

Your coil, which is generally water-cooled and made of copper, must follow the shape of your part and take the variables of your process into account. An optimum coil design will deliver the best heat pattern to your part in probably the most efficient way. A poorly designed coil will heat your part more slowly and deliver an improper heating pattern. Flexible coils are now available and work well with massive parts and distinctive part geometries.

 

 

7. Coupling Efficiency

 

The part being closely coupled with the coil elevates the flow of present, which will increase the quantity of heat generated within the part. Coupling enables faster and more environment friendly heating, which can improve manufacturing efficiency. Poor coupling has the opposite effect.

 

 

8. Your Facility and the Footprint

 

Induction requires cooling from a chiller or cooling system. Lower-power systems typically require a compact water-to-air heat exchanger, while a higher-energy system could require a bigger water-to-water heat exchanger or chiller. Additionally, you will need house for the induction heating energy supply and workhead. Usually speaking, an induction system will save considerable house over an oven, particularly while you consider that the workhead might be positioned a significant distance away from the ability supply. In fact, you additionally should be positive your facility can deal with the quantity of power the system requires.

 

 

9. Additional Heating Necessities

 

Will it's good to measure and store heating data? Some induction resolution providers can offer a full system that includes an optical pyrometer and temperature-monitoring software so such data might be recorded and stored. A complete resolution can lead to a smooth set up and start-up.

 

 

10. Industrial Experience

 

Many induction producers have experience with sure applications, and in the event that they’ve worked with your application, it will provide peace of mind. Additionally, some providers supply laboratory testing and a tailored system recommendation based mostly in your heating requirements. This type of service takes the guesswork out of choosing a system and helps you account for the aforementioned factors.

 

 

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