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

Power Supply

Power, expressed in kilowatts (kW), refers to the induction power-provide size. A power supply have to be sized to heat a given mass or given surface area to a specific temperature within a specified time. A general rule of thumb is that the surface area (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 facility density (kW/inch2) required. For example, a quench-and-tempered microstructure is optimum for most induction applications.

More energy is not necessarily better. Matching the ability and frequency is the key. While more power enables you to heat faster, it may additionally soften the surface or produce a deeper sample (there is additionally more hazard of by hardening), and it is harder to control grain growth.

Frequency

High frequency in the form of alternating current is passed through 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 supply 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-particular and dependent on each energy density and heat time however is considered typical of what’s discovered within 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 function of part diameter and the resistivity of the material. There may be an optimum depth of current penetration range, which is what each producer strives to provide.

Higher frequency has a definite advantage when you’ve gotten marginal prior part microstructures (annealed or normalized). Higher frequency allows the focus of more energy near the surface of the part, avoiding lengthy heating occasions or necessities for higher power density (more expensive by way of $/kW).

Tuning

Tuning (energy-provide load matching) is a vital 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 power supply.

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

Computer-managed and recipe-selected computerized capacitor contactors can be used to load match when many various workpiece sizes are heat handled on the same piece of equipment. Many power-provide manufacturers design a tuning window that permits you to make some adjustments 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 workitems have their own function, form 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 requirements and production rates of the workpiece. Coils require periodic maintenance (repair) and must be suitable for the applications whether it be scanning, static heating or single-shot heating.

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