INDUCTION HEATING METHOD
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Inductor |
If you want to heat
metal parts with high accuracy, high speed of work, consistent performance, 90%
efficient, low noise, no fumes and without any exposed flames then the machine
known as induction heating is most preferred choice for all industries.
The induction heating
procedure is the most preferred one than any other heating technique. The
induction heating system is good for industrial hardening, galvanising,
alleviating, brazing and heat staking. This technology is also suitable for
non-metals with proper setup. This technology can be easily fit for all
manufacturing floors of industries and also whether the requirement is high
heat or used for the fully automated plant, this is the desired solution for
all industries.
It is a process of
hardening, softening and jointing two or more different metals. The induction
operation is also suitable for the non-conductive materials with proper setups.
That procedure was used in a year of 1920’s in World War 2 where it was used for
the hardening of machine engines in a mean time. On the basis of that preceding
technology, induction system has been revolutionised.
It is a unique system
than any other heating method because in other heating strategies like open
flame, is directly applied on the metal parts but in case of induction heating,
a heat is induced in the material by means of a current circulating in it.
Induction heating works
on the RF frequency that is below the infrared and microwave frequencies. It
means that heat is transferred to the material by means of electromagnetic
waves. There is no contact between inductor and a material. The inductor does
not heat up and a product is moved inside an inductor. The process will flow in
a smooth way by repeating same strategy.
Faraday's
Law of Electromagnetic Induction
Now I am going to
describe how that process will work. It is just a fundamental principle of
electricity. Consider an AC current is supplied to a primary winding of a
transformer due to that magnetic flux creates in it. There is also a magnetic
field arises. If the secondary coil is in the vicinity of magnetic flux created
in primary winding then a current is induced in it. This whole process is
simply called a ‘Faradays Law of Electromagnetic Induction’.
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Basic Setup |
In the diagram shown to
the right, simply constitute an RF supply source that sends an AC current to
the inductor made up of copper and a metal that is to be heated is placed
inside it. The inductor serves as a primary winding and a metal is considered
as a secondary short circuit. So a magnetic field of inductor links with the
metal and a closed eddy currents are induced in it
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Induction Heating Principle |
In the second figure
shown to the right shows the eddy current flow against to the resistivity of
the metal that is to be heated and there is no contact between them. The heating
can be applied to magnetic and non-magnetic materials and is known as ‘Joule’s
Effect’.
As there is no physical
contact between them so the metal that is to be heated is placed in a liquid,
away from power supply, in gassy atmosphere or in a space.
Advantages
of Induction machine
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Induction Heating Machine |
The performance is
consistent as compared to other heating methods such as torch or open flame
heating. When you set up the calibration then the pattern of heating is continuous
and constant. Modern machines have a temperature
control systems that turns on or turn off the power supply and providing constant
results. It is also capable of providing temperature data of each individual
part.
A production is maximum
as there is no time needed for it to warm up or cool down. A heat of about
greater than 2000 ⁰F
is developed instantly within the part in less than 1 second.
- Minimum
Chances of Rejection
As there is no direct
contact with a flame and heat is produced in a material by the alternating
electric current in itself. So there is s a minimum chance of rejection ratio
and a part is placed in an isolated substance or in a vacuum to diminish the effects
of corrosion.
Supply heat to the
specific part between two materials and increases the durability of life.
No fumes of gases
evolved and no intense noise during heating so it is friendly to the worker as
well as for the environment.
It consumes less energy
as 90% of the energy is converted into heat.