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

Power Supply

Power, expressed in kilowatts (kW), refers back to the induction energy-provide size. A power provide should be sized to heat a given mass or given surface area to a specific temperature within a specified time. A basic rule of thumb is that the surface area (uncovered 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 power will not be necessarily better. Matching the power and frequency is the key. While more power enables you to heat faster, it can also soften the surface or produce a deeper pattern (there’s also 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 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 next guideline for “relative” depth of penetration (depth of hardening or case depth) as a function of frequency is likely to be useful. This information is application-specific and depending on each power density and heat time however is considered typical of what is found within the industry:

@ 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 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 distinct advantage when you will have marginal prior part microstructures (annealed or normalized). Higher frequency permits the focus of more energy near the surface of the part, avoiding lengthy heating times or requirements for higher power density (more pricey when it comes to $/kW).

Tuning

Tuning (energy-supply load matching) is a very important consideration to achieve the desired case-depth profiles and for total power-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 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 essential as power levels approach the maximum nameplate ranking of the ability supply. For consistency of heating, the ability provide ought to be tuned so that it just isn’t running to its limit.

Computer-controlled and recipe-selected automatic capacitor contactors can be used to load match when many various workpiece sizes are heat treated on the same piece of equipment. Many power-provide manufacturers design a tuning window that means that you can make some modifications 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 perform, shape and properties. Coils (inductors) are water-cooled copper tubing or machined from solid copper blocks. They’re designed and built specifically to fulfill the metallurgical requirements and production rates of the workpiece. Coils require periodic maintenance (repair) and must be suitable for the applications whether or not it be scanning, static heating or single-shot heating.

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