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Induction heating equipment is a type of areas that many people need to know more about. We need to know when and the right way to apply this technology, if it is the correct one for the job and the best way to purchase it if we have to do so. Let’s study more.

Power Supply

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

More power isn’t essentially better. Matching the ability and frequency is the key. While more power enables you to heat faster, it might also melt the surface or produce a deeper pattern (there may be additionally more hazard of by way of hardening), and it is harder to regulate grain growth.

Frequency

High frequency within the form of alternating current is passed by the coil to create a magnetic area producing eddy currents. These are generated within the metal under the surface, and the resistance to this present 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 perform of frequency is perhaps useful. This information is application-specific and dependent on each energy density and heat time however is considered typical of what is found in the business:

@ 450 kHz the case depth developed is (approximately): 0.030-0.040 inch

@ a 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 perform of part diameter and the resistivity of the material. There’s an optimum depth of current penetration range, which is what each manufacturer strives to provide.

Higher frequency has a definite advantage when you’ve got 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 times or requirements for higher power density (more costly by way of $/kW).

Tuning

Tuning (energy-provide load matching) is a very important consideration to achieve the desired case-depth profiles and for overall energy-system efficiency. This is completed 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 power supply.

The goal is to have a system that requires a minimal quantity of tuning, which becomes more essential as energy levels approach the maximum nameplate rating of the power supply. For consistency of heating, the power supply must be tuned in order that it shouldn’t be running to its limit.

Computer-controlled and recipe-chosen automated capacitor contactors can be used to load match when many different workpiece sizes are heat handled on the same piece of equipment. Many energy-provide manufacturers design a tuning window that permits you to make some changes 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 function, form and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They’re designed and constructed specifically to meet the metallurgical requirements 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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