Induction heating has considerable advantages over other common heating methods in specific applications. Is yours one of those applications?
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Induction heating offers many benefits to manufacturing processes because it is a rapid, energy-efficient, flameless method of heating electrically conductive materials. A typical system involves an induction power supply, workhead with a copper coil and a chiller or cooling system. Current flows through the coil to create an electromagnetic alternating field. When a conductive part is placed inside the coil, current is induced to run through it. Current flow combined with the resistance properties of the conductive part results in heat generation.
10 Selection factors to consider
Your Part's Material
Induction directly heats conductive materials such as metals. Nonconductive materials are sometimes heated with a conductive susceptor. Due to hysteresis, magnetic materials are heated more easily than nonmagnetic materials; consequently, nonmagnetic materials often require more power. Metals with high resistivity like steel heat quickly, while low-resistivity metals like copper or aluminum require more heating time.
Depth of Heating Penetration
The induced current will be most intense on the surface of your part. In fact, more than 80% of the heat produced in the part is produced on the 'skin,' or surface. Consequently, larger parts and parts that require through-heating take more time to heat than those that are thin or small.
Operating Frequency
Lower-frequency, higher-power systems are generally suited for heating larger parts that require through heating. Lower-power, higher-frequency systems are often the right choice for surface heating. As a general rule, the higher the frequency, the shallower the heating of the part.
Applied Power
The output power of your induction heating power supply determines the relative speed at which your part is heated. The mass of the part, rise in temperature and heat losses from convection and conduction need to be considered. Often, the induction equipment manufacturer can help you make this assessment.
Rise in Temperature Required
Induction can generate a significant change in temperature, but, generally speaking, more power is needed to accommodate a significant temperature change and will impact your power-supply choice. The rate of temperature change also affects your power-supply choice. The faster the rate of change, the more significant the power requirement.
Coil Design
Your coil, which is generally water-cooled and made of copper, needs to follow the shape of your part and take the variables of your process into account. An optimal coil design will deliver the right heat pattern to your part in the most efficient way. A poorly designed coil will heat your part more slowly and deliver an improper heating pattern. Flexible coils are now available and work well with large parts and unique part geometries.
Coupling Efficiency
The part being closely coupled with the coil elevates the flow of current, which increases the amount of heat generated in the part. Coupling enables faster and more efficient heating, which can increase manufacturing efficiency. Poor coupling has the opposite effect.
Your Facility and the Footprint
Induction requires cooling from a chiller or cooling system. Lower-power systems generally require a compact water-to-air heat exchanger, while a higher-power system may require a larger water-to-water heat exchanger or chiller. Additionally, you will need space for the induction heating power supply and workhead. Generally speaking, an induction system will save considerable space over an oven, especially when you consider that the workhead can be placed a significant distance away from the power supply. Of course, you also need to be sure your facility can handle the amount of power the system requires.
Additional Heating Requirements
Will you need to measure and store heating data? Some induction solution providers can offer a full system that includes an optical pyrometer and temperature-monitoring software so such data can be recorded and stored. A comprehensive solution can lead to a smooth installation and start-up.
Industrial Expertise
Many induction manufacturers have expertise with certain applications, and if they've worked with your application, it will provide peace of mind. Additionally, some providers offer laboratory testing and a tailored system recommendation based on your heating requirements. This type of service takes the guesswork out of selecting a system and helps you account for the aforementioned factors.
In conclusion, induction heating has considerable advantages over other common heating methods. Buying the right system for your application's needs and ensuring it meets any needs you may have for it in the future will help your company fully benefit.
Note: This article was originally published as a cover feature in Industrial Heating (which has ceased publishing) via a submission from Ambrell.
Are there water quality requirements?
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The following are recommendations for water quality for use with UPT induction Systems to ensure a long service life of the equipment.
As many as 80% of problems with Induction Heating equipment can be traced to water related issues, so maintaining the water system is critical to ensure high reliability. Failure to meet these water guidelines can void the warranty of the equipment. Ultraflex Power Technologies recommends the use of isolated water loops for our Induction Heating equipment. Use of plant water directly in our products can void the warranty. Water to Air, Chillers, and Water to Water systems are available from UPT, please contact your sales associate for more details.
1) Use clean distilled water, if possible. The following are the recommended water quality specifications:
SpecificationRecommendedNot to ExceedTotal Hardness (CaCO3)15 ppm100 ppmTotal Dissolved Solids25 ppm200 ppmConductivity*<50
μ
S/cm
>50
μ
S/cm
Max Suspended Solids<10 ppm>10 ppmPH**7.0-7.5<7.0 >7.5
* Water conductivity that is too low (e.g. De-ionized Water) is not recommended.
** If the pH falls below 4.0 or rises above 9.0, the system should not be used and a system flush/fill should take place as soon as possible.
a. Never use de-ionized (DI) water, as it will damage the aluminum, copper, and bronze fittings.
b. Glycol can help keep the water from becoming too aggressive. If used, a 30% ethylene glycol (nonconductive type) mixture is recommended with clean water as defined above.
c. Phosphate based corrosion inhibitors are recommended to control the amounts of active ions and help form protective oxide layers on metals.
2) The Ultraflex Power Technology water circuits contain aluminum, brass, copper, rubber, and plastic hose.
a. Ensure dissimilar metals are not used in the water system. The water system should be designed with compatible metals to avoid contamination from items that may rust. Never use ferrous materials in the water loop such as carbon steel, which will increase conductivity and cause rust and corrosion.
b. While Nonmagnetic Stainless Steel can be used in the water system, it should be located a sufficient distance from the induction heating system to avoid galvanic corrosion between the other metals in the systems such as Aluminum.
c. Water should not be used for other equipment or processes to avoid contamination. In particular, do not use process water for cooling workpieces that are exposed to the environment and contaminants. If some minor contaminants are possible, the customer should install an in-line strainer to capture suspended particles (> 304 microns).
4) Good water quality requires regular maintenance
a. PH and conductivity levels should be checked quarterly and adjusted as needed.
b. The water system should be flushed to remove sediment and treated with an anti-algae treatment as needed.
c. The water in the closed loop should be changed at least annually and more often if quality deteriorates.
d. Additional maintenance per the manufacturer recommendations should be followed.
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