induction heating system technology PDF

Induction Heating Technology Review

1. Introduction

All IH (induction heating) applied systems are developed using electromagnetic induction which was first discovered by Michael Faraday in 1831. Electromagnetic induction heating refers to the phenom- enon by which electric current is generated in a closed circuit by the fluctuation of current in another circuit placed next to it. The basic principle of induction heating, which is an applied form of Faraday’s discovery, is the fact that AC current flowing through a circuit affects the magnetic movement of a secondary circuit located near it. The fluctuation of current inside the primary circuit provided the answer as to how the mysterious current is generated in the neighboring secondary circuit. Faraday’s discovery led to the development of electric motors, generators, transformers, and wireless communications devices. Its application, however, has not been flawless. Heat loss, which occurs during the induction heating process, was a major headache undermining the overall functionality of a system. Researchers sought to minimize heat loss by laminating the magnetic frames placed inside the motor or transformer. Faraday’s Law was followed by a series of more advanced discoveries such as Lentz’s Law. This law explains the fact that inductive current flows inverse to the direction of changes in induction magnetic movement.

Heat loss, occurring in the process of electromagnetic induction, could be turned into productive heat energy in an electric induction heating system by applying this law. Many industries have benefited from this new breakthrough by implementing induction heating for furnacing, induction quenching, and weld- ing. In these applications, induction heating has made it easier to set the heating parameters with- out the need of an additional external power source. This substantially reduces heat loss while maintaining a more convenient working environment. Absence of any physical contact to heating devices precludes unpleasant electrical accidents. High energy density is achieved by generating sufficient heat energy within a relatively short period of time……

Induction Heating System Technology

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PDF of Induction Heating Principle and Applicatons

Induction Heating Principle and Applications PDF download for Research

Electromagnetic induction, simply induction, is a heating technique for electrical conductive materials

(metals). Induction heating is frequently applied in several thermal processes such as the melting and

the heating of metals.

Induction heating has the important characteristic that the heat is generated in the material to be heated itself. Because of this, induction has a number of intrinsic trumps, such as a very quickheated itself. Because of this, induction has a number of intrinsic trumps, such as a very quick response and a good efficiency. Induction heating also allows heating very locally. Tare extremely high because of the high power density…..

induction heating principle and applications

 

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induction small copper tubing brazing connection joints

Objective

Full solid high frequency induction small copper tubing brazing connection joints using the DW-UHF-10 kW induction brazing system and available split lab coil

Test 1

Equipment

DW-UHF-10kw induction brazing machine

Materials

• Copper tubing – Suction Tube

• Braze paste

Key Parameters

Power: 9.58 kW

Temperature: Approximately 1500° F (815° C)

Time: 5 – 5.2 sec

Test 2

Equipment

 DW-UHF-10kw induction brazing system

Materials

• Copper tubing – Condenser tube

• Braze paste

Key Parameters

Power: 8.83 kW

Temperature: Approximately 1300° F (704° C)

Time: 2 sec

Process:

Test 1

As only one assembly was provided for the test, we set up a test load using a heavy wall 5/16” copper tubing set up such as one tube accepted the other at a formed open flange end. Heat time was estimated based on using tempilaque paint to indicate the temperature. The test assembly, (followed by the provided components) were assemble with a coating of 505 alloy braze paste and placed in the lab test coil per the attached photographs) A heat cycle 5 – 5.2 seconds was found to flow the alloy and make the joint.

Test 2:

The smaller tube assembly (condenser tube) was assembled and a ring from the supplied braze alloy (silver solder) was formed and place at the intersection of the two tube . A heat time of 2 seconds was sufficient to flow the alloy and complete the joint.

Results/Benefits:

1. As demonstrated, the DW-UHF-10kw induction brazing system is capable of induction heating both the largest and smallest tube to tube sections to complete a brazed joint. Heat times using an available test coil are within the production heat time expectations required by FLDWX


2. HLQ will require a full assembly for review in order to develop the final induction heating coils design that can accommodate all 12 joints indicated on your layout photograph. It is necessary to know and see the clearances between the tube connections to be brazed and the steel compressor section to insure that the steel housing is not affected by the resulting RF field created at the load coil. This final design may require the addition of ferrite materials in the coil that will serve to focus the RF field to the copper leads and not to the steel housing.


3. Initial tests were completed on the DW-UHF-10 kW utilizing an available lab coil. The production induction heating coil will be contained in a none-conductive housing that will permit the operator to use it to locate the coil against the copper leads for accurate and positive heating location for the braze process. The production coil design will incorporate shorter leads than the test coil and be configured such that the heat cycles will be improved (shorter heat times).

1. HLQ can provide the system with an optional process control. This will effectively be a programmed process cycle that will be developed for each joint listed on the assembly photograph supplied with the application request from FLDWX. Each of the 12 joints will be programmed sequentially to accommodate each particular joint – this will permit the operator to move in the same sequence as programmed from joint 1 to joint 12. Each cycle of the U induction brazing coil/handle will move the process from joint 1 (heat time and % of power) to joint 2 (heat time and % power) etc. though to joint 12. The sequence, once entered, would need to be followed for each assembly. This will take the guess work out of braze time per joint to provide repeatability in the process.

1. Another option for consideration would be to consider the HLQ Robotic Arm option. This option supports the induction brazing coils/ coil housing and actuates the assembly when programmed to place the coil at each joint area. The support arm rotates and moves the coil/coil housing to the proper position and angle for each joint assuring the soil position and heat time.

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induction brazing brass pipe to brass part

Objective

High Frequency Induction Brazing brass pipe to brass part and a brass tip in under one minute using induction.

Equipment

DW-UHF-6KW-III handheld induction brazing machine

2 turns coil

Materials

• Wide brass part

• Brass pipe

• Silver-based brazing alloy, provided by customer

Test 1 – Pipe to wide part:

Key Parameters

Power: 4.4 kW

Temperature: Approximately 1400° F (760° C)

Time: 38 sec

Test 2 – Pipe to tip:

Key Parameters

Power: 4.4 kW

Temperature: Approximately 1400° F (760° C)

Time: 17 sec

Process:

Test 1

• The wide part and brass pipe are assembled and a brazing alloy ring is placed between them.


• The assembly is put inside the induction heating coil and induction heat is applied.


• The joint is completed in 38 seconds.

Test 2

• The tip and pipe are assembled and a brazing alloy ring is placed between them.


• The assembly is put inside the coil and induction heat is applied.


• The joint is completed in 17 seconds.

Results/Benefits:

Induction heating provides:

• Strong durable joints


• Selective and precise heat zone, resulting in less part distortion and joint stress than welding


• Less oxidation


• Faster heating cycles


• More consistent results and suitability for large volume production, without the need for batch processing


• Safer process than flame brazing

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induction Brazing copper rods to brass strips

Objective

Induction Brazing copper rods to brass strips to replace torch operation. The current torch process results in excessive contaminants on the assembly, and requires extensive rework after the induction brazing operation.

Equipment

DW-UHF-10KW INDUCTION BRAZING MACHINE



Two turn open end conveyor coil

Materials

• Copper coupon plate and copper rod

• Braze wire – EZ Flo 45

• Braze alloy – 45% Silver, 1/32 DIA

Key Parameters – TEST 1

Power: 7.2 kW

Temperature: Approximately 1350° F (732° C)

Time: Average time – 100 seconds

Process and Results:

For Induction brazing copper plate to copper rod,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended. The assemblies were set up and heated for an average time of 100 seconds to flow the alloy and achieve the braze.

Key Parameters – TEST 1

Power: 6 kW

Temperature: Approximately 1350° F (732° C)

Time: Average time – 2.5 minutes

Process and Results:

For Induction brazing copper rod to brass plate,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended. The assemblies were set up (see photographs) and heated for an average time of 2.5 minutes to flow the alloy and achieve the braze.

Due to the metal resistance differential between copper and brass, the brass bar heat preferentially. The induction heating coil designed to braze the bars to the plate section heats the rods and the heat is transferred to the plate more by conduction than induction causing the bars to initially reach temperature prior to the plate. If the materials are the same (cooper to copper or brass to brass, this is not a problem. If the bar is copper and the plate is brass there are not issues – only when the bar is brass and the plate is copper. This requires the power to be reduced to allow tie for heat transfer from the brass rod to the copper plate.

Key Parameters – TEST 1

Power: 7.2 kW

Temperature: Approximately 1350° F (732° C)

Time: Average time – 2 minutes

Process and Results:

For Induction braze copper coupon plate and copper rod,, EZ Flo 45 braze wire was cut into 2” lengths and placed in the interface area. In a production situation, EZ Flo 45 brazing paste is recommended.

The assemblies were set up  and heated for an average time of 2 minutes to flow the alloy and achieve the braze.

Results/Benefits:

• induction brazing Strong durable joints


• Selective and precise heat zone, resulting in less part distortion and joint stress than welding


• Less oxidation


• Faster heating cycles


• More consistent results and suitability for large volume production, without the need for batch processing


• Safer than flame brazing

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induction brazing steel carbide cap to shaft

Objective

High Frequency Induction brazing steel carbide cap to shaft.  Customer currently uses a torch process, but would like to change to induction brazing in order to reduce scrap and rework and improve the quality of the braze.

Equipment

DW-UHF-6kw-III handheld induction brazing heater

Materials

• Carbon steel

• magnetic carbide caps

• Alloy – EZ Flo 3 paste

• Test 1: Shaft Diameter: 0.5” (12.7 mm)

• Test 2: Shaft Diameter: 0.375” (9.525mm)

• Test 3: Shaft Diameter: 0.312” (7.925mm)

Key Parameters

Test 1: Shaft Diameter: 0.5” (12.7mm)

Temperature: Approximately 1450°F (788°C)

Power: Pre-curie – 3.3 kW

Time: 11 seconds

Key Parameters

Test 2: Shaft Diameter: 0.375” (9.525mm)

Temperature: Approximately 1450°F (788°C)

Power: Pre-curie – 1.8 kW

Time: 8 seconds

Key Parameters

Test 3: Shaft Diameter: 0.312” (7.925mm)

Temperature: Approximately 1450°F (788°C)

Power: Pre-curie – 1.7 kW

Time: 7.5 seconds

Process:

1. Paste alloy was applied to the cone shape top of each steel shaft.


2. The cap was set on top and rotated to distribute the paste alloy.


3. Each assembly was positioned in the coil and heated.


4. Preliminary heat tests were conducted using tempilaq paint to estimate the heat cycle to 1450 degrees F.

Results/Benefits:

• Precise control of the time and temperature resulting in improved quality and consistent result


• Power on demand with rapid heat cycles


• Repeatable process, not operator dependent


• Safe induction heating with no open flames


• Energy efficient heating

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Brazing Aluminum Tubing to Aluminum Parts

Objective

The objective of the application test is induction brazing aluminum tubing to aluminum parts in less than 15 seconds. We have aluminum tubing and an aluminum “receiver”. The brazing alloy is an alloy ring, and has a flow temperature of 1030°F (554°C).

Equipment

DW-HF-15kw induction heating machine

 

induction heating machine HF-15

Induction heating coil

Materials

• Aluminum tube: 0.167” (4.242mm) OD, 0.108” (2.743mm) ID

• Aluminum component: ID .1675” (4.255mm), depth .288” (7.315mm),

chamfer at top area is 0.2375” (6.033mm) ID max

• Braze alloy in the form of two-turn alloy ring

• Flux

Key Parameters

Temperature: 1030°F (554°C)

Power: 5 kW

Time: 14 seconds

Process:

1. The Aluminum component and tube were assembled together with the alloy ring. Flux was added.


2. The part was positioned in the induction coil.


3. Several tests were conducted with different cycle times to confirm the heating time for a good braze.


4. At 15 seconds the assembly melted.


5. At 14 seconds, we had success for brazing aluminum to aluminum, and a good quality braze joint was achieved.

Results/Benefits:



The 5 kW induction heating system requested by the customer, will meet the customer’s time requirements for induction brazing.

• Precise control of the time and temperature


• Power on demand with rapid heat cycles


• Repeatable process, not operator dependent


• Safe induction heating with no open flames


• Energy efficient heating

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brazing copper plates overlay joints

Objective

The objective of the application test is to braze copper and brass plates overlay joints with induction to replace torch operation. Overylay joints may be brass to brass or copper to copper.

The current torch process results in excessive contaminants on the assembly and requires extensive rework after the brazing operation.

Equipment

DW-HF-25kw induction heating machine

 

Materials

• Copper and brass coupon plates

• Braze alloy – EZ Flo 45

Key Parameters – Copper plates

Power: 15 kW

Heat to Temp: Approximately 1350° F (732° C)

Time: Average time – 2 minutes

Process and Results:

1. EZ Flo 45 braze wire was cut into 2” (50.8mm) lengths and placed in the interface area.


2. The assemblies were set up (see photos) and heated with induction heating for an average time of 2 minutes to flow the alloy and achieve the braze.

Key Parameters –Copper Brass coupon plates

Power: 15 kW

Heat to temp: Approximately 1350° F (732° C)

Time: Average time – 2 minutes

Process and Results:

1. EZ Flo 45 braze wire was cut into 2” (50.8mm) lengths and placed in the interface area.


2. The assemblies were set up (see photos) and heated for an average time of 2 minutes to flow the alloy and achieve the induction brazing.

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brazing carbide tips

Objective

Induction brazing carbide tips onto milling cutter tools process

Equipment

DW-UHF-20kw induction brazing machine

Power: 11,5kW (max)

Time: 10 sec (to brazing temperature)

Process Steps

1. Induction Heating to brazing temperature to remove stale tool

2. Removing old solder during heating

3. Braze new tool

Results and Conclusions:

1. The delivered power to the load was more than enough and the test was performed successful

2. Coil bar connection between customer induction coil and our heat station was only for test purposes

3. Using of foot-switch for this application is useful for this application

Conclusions:

The induction heating machine performance exceeds customer expectations. The customer was very happy to reduce the time needed for worn carbide tips replacement.

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