Induction Heating Machine

INDUCTION HEATING METHOD

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’.        

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   

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

• Consistent Performance

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.

• Maximum Production

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.

• Increase Durability

Supply heat to the specific part between two materials and increases the durability of life.       

• Environmentally Friendly

No fumes of gases evolved and no intense noise during heating so it is friendly to the worker as well as for the environment.

• Energy Consumption

It consumes less energy as 90% of the energy is converted into heat.