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How does Induction Heating Work?
Induction heating creates heat directly in the part to be heated. A generator, (usually solid state), creates a high frequency current in a coil winding. The electrical current in the coil creates a high frequency magnetic field primarily inside the coil. Any conductor placed inside the coil will be immersed in the magnetic field. The magnetic field causes an electric current to flow in the part, which results in self heating due to the heated parts own internal electrical resistance. There is no contact between the coil winding and the part being heated.
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What can be heated using Induction?
A common misconception is that only magnetic metals can be heated. Any electrical conductor can be heated using induction. Items that are non conductive, (insulators), can only be heated indirectly. Many thermoset adhesives and epoxies are indirectly heated. Usually a metal is in contact with the insulator being heated. Aluminum foil liners are glued to plastic bottles, (food and pharmaceuticals), using induction to heat the aluminum and indirectly heat the adhesive. Induction heating is commonly used in heating applications such as forging, heat treating, and melting.
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What are the advantages of Induction Heating?
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Much faster heating of the part than with gas fired. Power density available with induction is almost unlimited.
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Very easy to control the temperature of the part. Process control is integral to induction and can be changed immediately on the fly with little or no time delay.
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Full power and temperature upon demand. There is no warm up time.
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No power is required during stand by.
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Environmentally clean.
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Working environment is substantially improved.
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Very suitable for automatic handling systems.
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Do I need three phase incoming power?
Most induction heating systems require three phase power.
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Why do I need cooling water?
All induction systems are not necessarily water cooled. Those that are, use water cooling to allow the power components to operate much cooler than is possible with air cooling. The BTU content of water per degree temperature rise is much higher than that of air.
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Do I need special cooling water?
Yes. The cleaner the water the better, regardless of the type of induction heating equipment that is used. Distilled or de-ionized water is best. Don’t let anyone tell you an induction machine doesn’t need clean water. When it comes to a cooling system, if electrolysis isn’t an issue, mineral deposits are.
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What is the
lifetime of induction heating equipment?
Solid state systems in theory could last indefinitely as there are no moving parts to wear. In reality however, a 10 to 15 year life is a reasonable period to assume, provided good quality water and proper maintenance are applied.
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Does my part have to fit completely inside a coil?
No, there are coils that do not encircle a part. One can use a channel, pancake, or hairpin coils for example.
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Can I heat many different sizes of parts with the same coil?
Many sizes of parts may be heated in a single coil. To maximize efficiency, a heated part should be as closely coupled with the coil winding as reasonable. The smaller a part is in a given coil, the less efficient the heating is.
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How fast can I heat a part?
This common question has the most varied and complex range of answers. Simply stated, product heating rate is directly proportional to the power applied and inversely proportional to the weight of the part. One cannot increase power input without limit. In through heating there must be time for the heat to soak to the center of the part. But, with the proper selection of frequency soak time can be reduced.
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Where can I get more information on induction heating?
Listed below are excellent books for induction basics:
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Basics of Induction Heating
Volumes 1 & 2
Chester A. Tudbury, M.S.
Copyright May 1960, John F. Rider, Publisher, New York
Library of Congress No. 60-8958
Available from University Microfilms (Out of Print Books)
300 North Zeeb Road
Ann Arbor, MI 48106
800-521-0600
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Induction Heating Handbook
John Davies and Peter Simpson
Copyright 1979
McGraw Hill Publishing
Library of Congress No. TK4601.D38 621.4’02 78-7279
ISBN No. 0-07-084515-8
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Elements of Induction Heating
Stanley Zinn and S. Lee Semiatin
Copyright 1988
Electric Power Research Institute, Palo Alto, CA 94303
and
ASM International, Metals Park, OH 44073
Library of Congress No. 4601.Z56 1987
ISBN No. 0-87170-308-4
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Providing
Field Proven Induction Heating Products Worldwide Since
1984 |
