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Suggestions for Choosing Induction Heating Equipment
Induction heating equipment is a type of areas that many of us have to know more about. We need to know when and the right way to apply this technology, if it is the appropriate one for the job and the best way to buy it if we have to do so. Let’s learn more.
Power Supply
Power, expressed in kilowatts (kW), refers back to the induction power-provide size. A power provide have to be sized to heat a given mass or given surface space to a specific temperature within a specified time. A normal rule of thumb is that the surface space (exposed to the coil) used to determine the ability level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will influence the power density (kW/inch2) required. For instance, a quench-and-tempered microstructure is optimum for most induction applications.
More energy will not be essentially better. Matching the ability and frequency is the key. While more power allows you to heat faster, it may additionally melt the surface or produce a deeper pattern (there is additionally more danger of by means of hardening), and it is harder to manage grain growth.
Frequency
High frequency in 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 function of frequency could be useful. This information is application-particular and depending on both power density and heat time however is considered typical of what's discovered 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.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 operate of part diameter and the resistivity of the material. There is an optimum depth of current penetration range, which is what each manufacturer strives to provide.
Higher frequency has a definite advantage when you might have marginal prior part microstructures (annealed or normalized). Higher frequency allows the concentration of more energy near the surface of the part, avoiding long heating instances or necessities for higher energy density (more expensive in terms of $/kW).
Tuning
Tuning (power-provide load matching) is a vital consideration to achieve the desired case-depth profiles and for general energy-system efficiency. This is finished by adjusting the tap 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 ability supply.
The goal is to have a system that requires a minimal quantity of tuning, which becomes more necessary as power levels approach the utmost nameplate ranking of the ability supply. For consistency of heating, the facility supply should be tuned in order that it just isn't 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 treated on the identical piece of equipment. Many energy-supply producers design a tuning window that lets you make some adjustments 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 stable copper blocks. They are designed and built specifically to fulfill the metallurgical requirements and production rates of the workpiece. Coils require periodic upkeep (repair) and must be suitable for the applications whether it be scanning, static heating or single-shot heating.
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Website: https://www.cmheat.com/
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