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Induction heating equipment is a kind of areas that many people need to know more about. We have to know when and easy methods to apply this technology, if it is the right one for the job and easy methods to buy it if we have to do so. Let’s learn more.

Power Supply

Power, expressed in kilowatts (kW), refers to the induction power-supply 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 find out the facility level is 6-12 kW/inch2. The prior part microstructure (annealed, normalized, quenched and tempered) will affect the ability density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for many induction applications.

More power is not essentially better. Matching the power and frequency is the key. While more energy permits you to heat faster, it may also melt the surface or produce a deeper pattern (there’s also more hazard of by hardening), and it is harder to control grain growth.

Frequency

High frequency in the form of alternating present is passed by means of the coil to create a magnetic discipline 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 function of frequency may be useful. This information is application-particular and depending on each power density and heat time however is considered typical of what is 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.a hundred and twenty inch

@ 10 kHz the case depth developed is (approximately): 0.090–0.200 inch

The depth of present penetration (hardened depth) is a function of part diameter and the resistivity of the material. There’s an optimum depth of present penetration range, which is what each manufacturer strives to provide.

Higher frequency has a definite advantage when you have got marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy near the surface of the part, avoiding lengthy heating instances or requirements for higher energy density (more costly when it comes to $/kW).

Tuning

Tuning (power-provide load matching) is a very important consideration to achieve the desired case-depth profiles and for overall power-system efficiency. This is done 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 seen on a meter panel on the facility supply.

The goal is to have a system that requires a minimal amount of tuning, which becomes more vital as energy levels approach the maximum nameplate score of the facility supply. For consistency of heating, the power supply ought to be tuned so that it just isn’t running to its limit.

Computer-controlled and recipe-selected automated capacitor contactors can be used to load match when many various workpiece sizes are heat handled on the same piece of equipment. Many energy-supply manufacturers design a tuning window that permits you to make some modifications to the part size 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’re designed and constructed specifically to fulfill the metallurgical necessities 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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