induction heating steel cable for cutting

induction heating steel cable for cutting with radio frequency heating equipment Objective Prior to cutting, heat a short section of a hardened steel cable coated with a polyethylene sheathing. Material Multi-strand braided stainless steel cable 0.5 in. (1.27 cm) OD enclosed within a polyethylene sheathing Temperature 1800 ºF (982) ºC Frequency 240 kHz Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing four (4) 1.0 μF capacitors (for a total of 1.0 μF). • An induction heating coil designed and developed specifically for this application. Process A three-turn helical coil is used to heat the cable in approximately 2 seconds. After the power is turned off, the heat is then transferred to the sheathing. Results/Benefits Induction heating provides a quick, precise repeatable method to reach the high temperature required. It is a very efficient heating method.  

Brazing Joining Copper Connectors With Induction

Brazing Joining Copper Connectors With Induction Objective: Brazing a joint between a copper lug and nickel plated copper pins on a pressurized heater connector. Material: 1.5” (38.1mm) dia heater connector in a ceramic insulator with L shaped copper lugs and nickel plated copper pins, silver solder and braze Temperature 1175-1375 ºF (635-746 ºC) Frequency 270 kHz Equipment • DW-UHF-10 kW induction heating system, equipped with a remote workhead containing two 1.5μF capacitors for a total of 0.75μF • An induction heating coil designed and developed specifically for this application. Process A two turn helical coil is used to heat the copper lugs and nickel plated copper pins for 1 minute. A clamp is used in production to hold the copper lugs in place for brazing. Results/Benefits Induction heating provides: • Minimal transfer of heat to adjacent ceramic insulator. • Hands-free heating that involves minimal operator skill for manufacturing. • Flameless processing. • Heat very small precise areas within production tolerances. • Even distribution of heating.

Aluminium Scraps Recycling Melting and Process

Aluminium Scraps Recycling Melting is the process by which scraps aluminium can be reused in products after its initial production. The process involves simply re-melting the metal, which is far less expensive and energy-intensive than creating new aluminium through the electrolysis of aluminium oxide (Al2O3), which must first be mined from bauxite ore and then refined using the Bayer process. Recycling scraps aluminium requires only 5% of the energy used to make new aluminium from the raw ore. For this reason, approximately 36% of all aluminium produced in the United States comes from old recycled scrap. Used beverage containers are the largest component of processed aluminum scraps, and most of it is manufactured back into aluminium cans. HLQ Induction Equipment Co provides the leading Aluminium Scraps Recycling Melting Furnace for recycling aluminium Scraps/cans/ingots and dross for industry aluminum recycling filed. Operation Steps:

• A Aluminum scraps/ingots/cans recycling furnace operator will place aluminum parts or aluminum ingot/scrap as a charge in the induction melting aluminum recycling furnace and start the furnace to begin the melting process. Adding more aluminum charge this process is advisable as molten aluminum transmits the heat better.
• When temperature of the aluminum reaches 1220.66°F it turns to liquid. Any residue from the coating and paint from the cans will float on the surface. This byproduct is called dross and can be skimmed by a steel ladle. This needs to cool before it can be disposed off safely.
• Next, the crucible (furnace) will pour out pure aluminum. Usually, Hydraulic tilting mechanism provided to pour large quantities of liquid metals.
• Finally, with care, the molten aluminum will be poured into mould to cool down and then slide out for use.

Advantages of induction aluminum scraps recycling furnace: 1, save energy and reduce the environmental temperature Original diesel furnace workshop on pollution, but also the auxiliary exhaust pipeline, inside and outside the furnace heat has a large number of distribution in the workshop, resulting in high temperature workshop. So is the original furnace condition, most escapes to the air, there is heat conduction loss, the production of large power consumption, increase the cost of production. At the same time, the ambient temperature increases. The electromagnetic induction heating process, the heating element is through magnetic field heating, in order to reduce the loss of heat conduction, fast heating, melting rapidly, thus reducing energy consumption. Reduce electricity consumption. After the comparison of the experimental test and modification, the power saving effect is 20%-40%. 2, rapid heating, temperature control accurate real-time Electromagnetic induction heating method is through the magnetic field lines make heating rapid heating, the rapid melting Aluminum Alloy. The temperature control is real-time and accurate, which improves the quality of the product and improves the production efficiency! 3 and long service life, simple maintenance The traditional electric melting induction furnace heating method is to use resistance wire heating, resistance wire in the high temperature environment for a long time in the use of oxidation will result in reducing its service life, high maintenance costs. The electromagnetic heating coil is made of insulating material and high temperature wire, so the service life is long and without any maintenance. 4, power Electromagnetic induction heating with the development and maturity of the technology, the production process and technology of components, software, such as reliable protection of the current power can be 2-200KW. 5, safe The utility model adopts the electromagnetic induction heating, which can reduce the surface temperature of the machine, and the human body can be safely touched, so as to avoid the occurrence of burn and scald accidents caused by the traditional heating mode and protect the production safety of the employees. Features 1 energy saving and environmental protection, Germany's IGBT power devices, high reliability, stable operation and low maintenance costs. 2) the frequency of the digital phase locked loop tracking, automatic load impedance matching. 3 power closed-loop control, to avoid the temperature change caused by the power down. 4) over voltage, under voltage, lack of phase, over current, over heat protection, real-time display of the parameters, fault diagnosis and alarm; leakage automatic alarm, cut off the power supply and the working state of real-time display. 5) PID heating control system, uniform heating temperature, prevent molten aluminum temperature drift, burning less, homogeneous metal components to improve the product qualification rate. 6 (LED) digital temperature controller, measuring and controlling the temperature accuracy of up to 3 degrees centigrade, the quality of aluminum soup is good, the melting temperature rises quickly, the furnace temperature is easy to control, the production efficiency is high; 7) the integral structure of polycrystalline mullite fibers of furnace, small volume, good insulation property, low energy consumption, high efficiency, temperature above 1200 degrees, long service life; 8. The operation is simple and the power can be adjusted with the work; 9 (100%) load duration, maximum power, to ensure the operation of 24 hours. Melting capacity of SMJD series electric aluminum scraps recycling melting furnace:  

Type	Input Power	Melting Capacity			Max Temperature
		steel, stainless steel	copper, gold, silver (scrap, Slag)	aluminum, aluminum alloy, Aluminum scrap, Aluminum slag, pop can	1800℃
SMJD-463	60 KW	200 KG	500 KG	200 KG
SMJD-480	60 KW	150 KG	500 KG	150 KG
SMJD-580	80 KW	200 KG	600 KG	200 KG
SMJD-600	60 KW	230 KG	560 KG	230 KG
SMJD-900	120 KW	300 KG	900 KG	300 KG
SMJD-905	80 KW	300 KG	900 KG	300 KG
SMJD-1250	80 KW	400 KG	1200 KG	400 KG
SMJD-1250	120 KW	450 KG	1350 KG	450 KG
SMJD-1500	120 KW	500 KG	1500 KG	500 KG
SMJD-1550	120 KW	520 KG	1560 KG	520 KG
SMJD-1700	160KW	600 KG	1700 KG	600 KG
SMJD-2300	160KW	800 KG	2000 KG	800 KG
SMJD-3100	200KW	1200 KG	3000 KG	1200 KG

[pdf-embedder url="https://dw-inductionheater.com/wp-content/uploads/2018/10/SMJD-melting-aluminum-furnace-parameter.pdf" title="SMJD melting aluminum furnace parameter"] [pdf-embedder url="https://dw-inductionheater.com/wp-content/uploads/2019/03/Aluminium-Scraps-Recycling-Melting-Process.pdf" title="Aluminium Scraps Recycling Melting Process"]

What Is Induction Heating Coil&Inductor?

What is induction heating coil & inductor? The varying magnetic field required for induction heating is developed in the induction heating coil via the flow of AC (alternating current) in the coil. The coil can be made in many shapes and sizes to custom fit a specific application. The coils can range from tiny coils made of copper tubing used for precise heating of extremely small parts in applications such as soldering and ferrule heating to large coil assemblies of copper tubing used in applications such as strip metal heating and pipe heating. What is the importance of the induction heating coil (inductor)? The induction coil design is one of the most important aspects of an induction heating system. The coil is a custom design to give your work piece or part the proper heating pattern, maximize efficiency of the induction heating power supply’s load matching system, and to accomplish these tasks while still permitting ease of loading and unloading your part.

Shrink Fit Steel Gear onto Shaft

Shrink Fit Steel Gear onto Shaft With High Frequency Induction Heating Units Objective Heat the bore of a hardened spur steel gear to shrink fit onto a gear motor shaft. This is part of a chair for the disabled. Material Steel gear 2.5” (63.5mm) OD, .75” (19mm) ID x .625” (16mm) thick, temperature indicating paint Temperature 400 ºF (204 ºC) Frequency 300 kHz Equipment • DW-UHF-3.2 kW induction heating system, equipped with a remote workhead containing two 0.66 μF capacitors for a total of 1.32 μF • An induction heating coil designed and developed specifically for this application. Process A four turn helical internal coil is used to heat the gear bore. The coil is inserted into the gear bore and power is applied for 90 seconds to reach the required 400 ºF (204 ºC) and expand the gear bore. The gear is then placed on the shaft and allowed to cool, creating the shrink fit between the gear and the shaft. Results/Benefits Induction heating provides: • No pre-heat cycle, heat is available on demand • Energy efficient, heats only the part, not the atmosphere around it • Controlled, even distribution of heating • Faster production times

Induction Annealing Copper Tubes

Simultaneously Induction Annealing Copper Tubes

Objective Uniformly heat two copper tubes simultaneously to 800°F (426°C) in under 10 seconds with induction heating.

Equipment DW-HF-45kw induction heater Helical coil Material • Two copper tubes – OD: 0.69’’ (1.75 cm) – ID: 0.55’’ (1.40 cm) – Length: 5.50’’ (14.0 cm). Key Parameters Power: 35kW Temperature: 842°F (450°C) Time: 7sec

Process:

1. The two copper tubes were placed together in the coil.
2. Induction heat was applied for 8s.

Results/Benefits:

• Improved process control for uniform heating to a desired temperature
• Power on demand and rapid, consistent heat cycles
• Technology without pollution, which is both clean and safe

Induction Hardening Surface Process

Induction Hardening Surface Process Applicatons

What is induction hardening ?

Induction hardening is a form of heat treatment in which a metal part with sufficient carbon content is heated in the induction field and then rapidly cooled. This increases both the hardness and brittleness of the part. Induction heating allows you to have localized heating to a pre-determined temperature and enables you to precisely control the hardening process. Process repeatability is thus guaranteed. Usually, induction hardening is applied to metal parts which need to have great surface wear resistance, while at the same time retaining their mechanical properties. After the induction hardening process is achieved, the metal workpiece needs to be quenched in water, oil or air inorder to obtain specific properties of the surface layer. Induction hardening is a method of quickly and selectively hardening the surface of a metal part. A copper coil carrying a significant level of alternating current is placed near (not touching) the part. Heat is generated at, and near the surface by eddy current and hysteresis losses. Quench, usually water-based with an addition such as a polymer, is directed at the part or it is submerged. This transforms the structure to martensite, which is much harder than the prior structure. A popular, modern type of induction hardening equipment is called a scanner. The part is held between centers, rotated, and passed through a progressive coil which provides both heat and quench. The quench is directed below the coil, so any given area of the part is rapidly cooled immediately following heating. Power level, dwell time, scan (feed) rate and other process variables are precisely controlled by a computer. Case hardening process used to increase wear resistance, surface hardness and fatigue life through creation of a hardened surface layer while maintaining an unaffected core microstructure.

Induction hardening is used to increase the mechanical properties of ferrous components in a specific area. Typical applications are powertrain, suspension, engine components and stampings. Induction hardening is excellent at repairing warranty claims / field failures. The primary benefits are improvements in strength, fatigue and wear resistance in a localised area without having to redesign the component.

Processes and Industries that can benefit from induction hardening:

• Heat-treatment
• Chain hardening
• Tube & Pipe Hardening
• Shipbuilding
• Aerospace
• Railway
• Automotive
• Renewable energies

Benefits of Induction Hardening:

Favoured for components that are subjected to heavy loading. Induction imparts a high surface hardness with a deep case capable of handling extremely high loads. Fatigue strength is increased by the development of a soft core surrounded by an extremely tough outer layer. These properties are desirable for parts that experience torsional loading and surfaces that experience impact forces. Induction processing is performed one part at a time allowing for very predictable dimensional movement from part to part.

• Precise control over temperature and hardening depth
• Controlled and localized heating
• Easily integrated into production lines
• Fast and repeatable process
• Each workpiece can be hardened by precise optimized parameters
• Energy-efficient process

Steel and stainless-steel components that can be hardened with induction: Fasteners, flanges, gears, bearings, tube, inner and outer races, crankshafts, camshafts, yokes, drive shafts, output shafts, spindles, torsion bars, slewing rings, wire, valves, rock drills, etc.

Increased Wear Resistance

There is a direct correlation between hardness and wear resistance. The wear resistance of a part increases significantly with induction hardening, assuming the initial state of the material was either annealed, or treated to a softer condition.

Increased Strength & Fatigue Life due to the Soft Core & Residual Compressive Stress at the Surface

The compressive stress (usually considered a positive attribute) is a result of the hardened structure near the surface occupying slightly more volume than the core and prior structure.

Parts may be Tempered after Induction Hardening to Adjust Hardness Level, as desired

As with any process producing a martensitic structure, tempering will lower hardness while decreasing brittleness.

Deep Case with Tough Core

Typical case depth is .030” - .120” which is deeper on average than processes such as carburizing, carbonitriding, and various forms of nitriding performed at sub-critical temperatures. For certain projects such as axels, or parts which are still useful even after much material has worn away, case depth may be up to ½ inch or greater.

Selective Hardening Process with No Masking Required

Areas with post-welding or post-machining stay soft - very few other heat treat processes are able to achieve this.

Relatively Minimal Distortion

Example: a shaft 1” Ø x 40” long, which has two evenly spaced journals, each 2” long requiring support of a load and wear resistance. Induction hardening is performed on just these surfaces, a total of 4” length. With a conventional method (or if we induction hardened the entire length for that matter), there would be significantly more warpage.

Allows use of Low Cost Steels such as 1045

The most popular steel utilized for parts to be induction hardened is 1045. It is readily machinable, low cost, and due to a carbon content of 0.45% nominal, it may be induction hardened to 58 HRC +. It also has a relatively low risk of cracking during treatment. Other popular materials for this process are 1141/1144, 4140, 4340, ETD150, and various cast irons.

Limitations of Induction Hardening

Requires an Induction Coil and Tooling which relates to the Part’s Geometry

Since the part-to-coil coupling distance is critical to heating efficiency, the coil’s size and contour must be carefully selected. While most treaters have an arsenal of basic coils to heat round shapes such as shafts, pins, rollers etc., some projects may require a custom coil, sometimes costing thousands of dollars. On medium to high volume projects, the benefit of reduced treatment cost per part may easily offset coil cost. In other cases, the engineering benefits of the process may outweigh cost concerns. Otherwise, for low volume projects the coil and tooling cost usually makes the process impractical if a new coil must be built. The part must also be supported in some manner during the treatment. Running between centers is a popular method for shaft type parts, but in many other cases custom tooling must be utilized.

Greater Likelihood of Cracking Compared to most Heat Treatment Processes

This is due to the rapid heating and quenching, also the tendency to create hot spots at features/edges such as: keyways, grooves, cross holes, threads.

Distortion with Induction Hardening

Distortion levels do tend to be greater than processes such as ion or gas nitriding, due to the rapid heat/quench and resultant martensitic transformation. That being said, induction hardening may produce less distortion than conventional heat treat, particularly when it’s only applied to a selected area.

Material Limitations with Induction Hardening

Since the induction hardening process does not normally involve diffusion of carbon or other elements, the material must contain enough carbon along with other elements to provide hardenability supporting martensitic transformation to the level of hardness desired. This typically means carbon is in the 0.40%+ range, producing hardness of 56 – 65 HRC. Lower carbon materials such as 8620 may be used with a resultant reduction in achievable hardness (40-45 HRC in this case). Steels such as 1008, 1010, 12L14, 1117 are typically not used due to the limited increase in hardness achievable.

Induction Hardening Surface Process details

Induction hardening is a process used for the surface hardening of steel and other alloy components. The parts to be heat treated are placed inside a copper coil and then heated above their transformation temperature by applying an alternating current to the coil. The alternating current in the coil induces an alternating magnetic field within the work piece which causes the outer surface of the part to heat to a temperature above the transformation range. The components are heated by means of an alternating magnetic field to a temperature within or above the transformation range followed by immediate quenching. It is an electromagnetic process using a copper inductor coil, which is fed a current at a specific frequency and power level.  

RPR Induction Stripping-Induction Rust & Paint Coating Removal

How Induction Stripping Works

Induction stripping is a hot surface preparation process.An induction generator sends alternating current through an induction coil, which generates an electromagnetic field. This field induces currents that are converted into heat in contact with conducting materials such as steel. The heat is generated beneath the coating, causing the coating to peel rapidly. This method is suitable for treating flat or curved surfaces on the jobsite and does not require any confinement. The induction stripping system will strip paint, other coatings, heavy rust, bacterial corrosion and oil and grease electrically conductive surfaces (ferromagnetic steel) breaking the interfacial bonding between the material and the substrate etch residues, induction heating localized and controlled which consumes minimal energy. HLQ simplifies your coatings removal needs with yet another revolutionary technology: Induction Stripping! HLQ’s induction stripping equipment removes your toughest coatings from steel structures with no noise or secondary waste—getting right down to the steel.

If you have ever wished for a magic wand to solve your coatings removal headaches, HLQ has the next best thing. HLQ technician can wave our induction wand over your coating catastrophe and dis-bond some of the hardest to remove coatings at rates that are up to 10 times faster than competing technologies like sandblasting.It’s not magic, but our induction stripping technology is a close second! When HLQ technicians move our induction head over a steel surface, it creates sufficient heat (typically 300 to 400 degrees) to quickly unbond most coatings from tanks, tankers, pipelines, ships and offshore platforms, allowing coatings (up to 1-inch thick) to be removed in sheets.

RPR Heat Induction Coating Removal

RPR Heat Induction coating removal works by the principle of induction. Heat is generated in the steel substrate and the bond at the steel and coating interface is broken. The coating is then removed entirely without disintegrating and completely free from contaminating agents, i.e.. blast media. This makes disposal and recycling of waste easier and more cost effective.   With minimum power consumption even the thickest and hardest coatings can be completely removed. RPR Heat Induction is faster than conventional methods. A silent method of coating removal means that our engineers can operate day or night with no noise pollution. Because of the many advantages of our induction heating process, we’ve been able to provide a wide range of Alliance customers with the service they need. We’ve worked with customers in industries such as:

• Oil & gas
• Financial
• Food & beverage processing
• Retail and food services
• Marine
• Hotels & hospitality
• Commercial pools and aquariums

HLQ’s jaw-dropping induction dis-bonding process removes most coating types, including:

• Coal Tar Epoxy
• Polyethylene
• Fiberglass

• Anti-skid
• Rubber
• Chartek fireproofing or other intumescent coatings

Faster, Quieter, Cleaner, Safer Surface Preparation

Some might say induction stripping is the “quick and dirty” way to get the job done, but truthfully it’s quick, and not messy at all. Because induction stripping creates no secondary waste, cleanup is simplified. Dealing with sheets or strips of coating is infinitely easier than dealing with blast media and dust.

In many cases, containment can be simplified or eliminated altogether. Imagine eliminating a costly scaffolding and containment project and replacing it with a snorkel lift and a drop cloth! Other trades can work in close proximity to HLQ’s induction stripping activities because it is a very quiet process that will not create obnoxious noises that disrupt the productivity of other contractors you may have working on your project. Our induction stripping equipment has no moving parts, making our process much safer than hydro-blasting or sandblasting for your employees, other contractors, customers and passersby.

Induction Coating Machine & Induction Paint Stripping System & RPR Induction System

 

What is induction hardening?

What is induction hardening? Induction hardening uses induced heat and rapid cooling (quenching) to increase the hardness and durability of steel.Induction heating is a no-contact process that quickly produces intense, localized and controllable heat. With induction, only the part to be hardened is heated. Optimizing process parameters such as heating cycles, frequencies and coil and quench design results in the best possible outcomes. What are the benefits? Induction hardening boosts throughput. It is an extremely fast and repeatable process that integrates easily into production lines. With induction it is usual to treat individual workpieces. This ensures each separate workpiece is hardened to its own precise specifications. The optimized process parameters for each workpiece can be stored on your servers. Induction hardening is clean, safe and typically has a small footprint. And because only the part of the component to be hardened is heated, it is extremely energy-efficient. Where is it used? Induction heating is used to harden numerous components. Here are just a few of them: gears, crankshafts, camshafts, drive shafts, output shafts, torsion bars, rocker arms, CV joints, tulips, valves, rock drills, slewing rings, inner and outer races.

Magnetic Induction Heater Manufacturer

Magnetic Induction Heater  is a process equipment which is used to melt,braze,forge,bond,heat treating,harden or soften metals or other conductive materials. For many modern manufacturing processes, Magnetic induction heating equipment offers an attractive combination of speed, consistency and control.The basic principles of magnetic induction heating have been understood and applied to manufacturing since the 1920s. During World War II, the technology developed rapidly to meet urgent wartime requirements for a fast, reliable process to harden metal engine parts. More recently, the focus on lean manufacturing techniques and emphasis on improved quality control have led to a rediscovery of induction technology, along with the development of precisely controlled, all solid state induction power supplies.

Magnetic Induction Heater relies on the unique characteristics of induction heating radio frequency (RF) energy - that portion of the electromagnetic spectrum below infrared and microwave energy. Since heat is transferred to the product via electromagnetic waves, the part never comes into direct contact with any flame, the inductor itself does not get hot, and there is no product contamination. When properly set up, the process becomes very repeatable and controllable.

Main Characteristics：

　  1.IGBT module and soft switiching inverting technologies are as in the production of the generator,higher reliability can be do.　

　  2. Small and portable ,compared with SCR controlled machine only 1/10 working space is needed. 3.  High efficiency to save energy,high efficiency and power far can be maintained

　  4.  The generator is adatable in a large frequency range from 1KHZ to 1100KHZ,installation can be done very easily according to our manual.　　

     5. 100%duty cycle ,continuous working ability at maximum power.　　

     6. Constant power or constant voltage control mode.

     7. Display of output power,output frequency,and output voltage.

Series	Model		Input power Max	Input current Max	Oscillate frequency	Input Voltage	Duty cycle
M . F .	DW-MF-15 Induction Generator		15KW	23A	1K-20KHZ According to the application	3*380V 380V±20%	100%
	DW-MF-25 Induction Generator		25KW	36A
	DW-MF-35Induction Generator		35KW	51A
	DW-MF-45 Induction Generator		45KW	68A
	DW-MF-70 Induction Generator		70KW	105A
	DW-MF-90 Induction Generator		90KW	135A
	DW-MF-110 Induction Generator		110KW	170A
	DW-MF-160 Induction Generator		160KW	240A
	DW-MF-45 Induction Heating Rod Forging Furnace		45KW	68A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-70 Induction Heating Rod Forging Furnace		70KW	105A
	DW-MF-90 Induction Heating Rod Forging Furnace		90KW	135A
	DW-MF-110 Induction Heating Rod Forging Furnace		110KW	170A
	DW-MF-160 Induction Heating Rod Forging Furnace		160KW	240A
	DW-MF-15   Induction Melting Furnace		15KW	23A	1K-20KHZ	3*380V 380V±20%	100%
	DW-MF-25   Induction Melting Furnace		25KW	36A
	DW-MF-35   Induction Melting Furnace		35KW	51A
	DW-MF-45   Induction Melting Furnace		45KW	68A
	DW-MF-70   Induction Melting Furnace		70KW	105A
	DW-MF-90   Induction Melting Furnace		90KW	135A
	DW-MF-110 Induction Melting Furnace		110KW	170A
	DW-MF-160 Induction Melting Furnace		160KW	240A
	DW-MF-110 Induction Hardening Equipment		110KW	170A	1K-8KHZ	3*380V 380V±20%	100%
	DW-MF-160Induction Hardening Equipment		160KW	240A
H . F .	DW-HF-04 Series	DW-HF-4KW-A	4KVA	15A	100-250KHZ	Single phase 220V	80%
	DW-HF-15 Series	DW-HF-15KW-A DW-HF-15KW-B	15KVA	32A	30-100KHZ	Single phase 220V	80%
	DW-HF-25 Series	DW-HF-25KW-A DW-HF-25KW-B	25KVA	23A	20-80KHZ	3*380V 380V±20%	100%
	DW-HF-35 Series	DW-HF-35KW-B	35KVA	51A
	DW-HF-45 Series	DW-HF-45KW-B	45KVA	68A
	DW-HF-60 Series	DW-HF-60KW-B	60KVA	105A
	DW-HF-80 Series	DW-HF-80KW-B	80KVA	130A
	DW-HF-90 Series	DW-HF-90KW-B	90KVA	160A
	DW-HF-120 Series	DW-HF-120KW-B	120KVA	200A
U . H . F .	DW-UHF-3.2KW		3.2KW	13A	1.1-2.0MHZ	Single phase220V ±10%	100%
	DW-UHF-4.5KW		4.5KW	20A
	DW-UHF-045T		4.5KW	20A
	DW-UHF-045L		4.5KW	20A
	DW-UHF-6KW-I		6.0KW	28A
	DW-UHF-6KW-II		6.0KW	28A
	DW-UHF-6KW-III		6.0KW	28A
	DW-UHF-10KW		10KW	15A	100-500KHZ	3*380V 380V±10%	100%
	DW-UHF-20KW		20KW	30A	50-250KHZ
	DW-UHF-30KW		30KW	45A	50-200KHZ
	DW-UHF-40KW		40KW	60A	50-200KHZ
	DW-UHF-6, 0KW		60KW	90A	50-150KHZ

Induction_heating_catalogue.pdf

Brazing Aluminum to Copper Tubes with Induction

Brazing Aluminum to Copper Tubes with Induction Objective: To heat an aluminum manifold to 1050 ºF (566 ºC) for a brazing application: Material :

• Cu tubes (3/4"/19mm)
• Cu tubes (5/8"/15.8mm)
• AI tubes (3/8"/9.5mm)
• AI manifold (5/8"/15.8mm)
• AI manifold (3/4"/19mm)
• Lucas-Milhaupt Handy One alloy 30-832
• Braze wire

Temperature 1050 ºF (566 ºC) Frequency 260 kHz Equipment DW-UHF-10KW 150-500 kHz induction heating system equipped with a remote heat station containing two 1.5 μF capacitors.

• A two-turn oval helical induction heating coil designed and developed specifically for the aluminum assembly
• A five-turn helical induction heating coil designed and developed specifically for brazing the Cu tubes to AI joint assembly

Process Braze : pre-forms were designed to fit the aluminum tubes. Then the four aluminum tubes were placed into the manifold and the assembly was inserted into the coil. The assembly was heated for approximately 70 seconds, at which point it reached the targeted temperature and braze flowed. For the Cu tubes, a braze pre-form was also designed for them, wound around the tubes, and the assembly was placed inside the coil. The heating cycle time was approximately 100 seconds. Some joints required stick feeding of braze to fill the entire joint area due to the braze wire size. If the cycle time was lengthened, the need for stick feeding would be eliminated. Results/Benefits: Precise, repeatable heating:

• The client wanted more precise and repeatable heating than a torch could deliver, which induction was able to achieve .
• Temperature control: Induction allows for superior temperature control when compared to other methods, including a torch, which the client desired

 

Aluminum Scrap Melting Recycling Induction Furnace

The top 200^1500kg Induction Aluminum Scrap Melting Recycling Induction Furnace for recycling and melting aluminum scraps,ingots,cans and dross material.

Operation Steps:

• An Aluminum scraps/ingots/cans recycling furnace operator will place aluminum parts or aluminum ingot/scrap as a charge in the induction melting aluminum recycling furnace and start the furnace to begin the melting process. Adding more aluminum charge this process is advisable as molten aluminum transmits the heat better.
• When temperature of the aluminum reaches 1220.66°F it turns to liquid. Any residue from the coating and paint from the cans will float on the surface. This byproduct is called dross and can be skimmed by a steel ladle. This needs to cool before it can be disposed off safely.
• Next, the crucible (furnace) will pour out pure aluminum. Usually, Hydraulic tilting mechanism provided to pour large quantities of liquid metals.
• Finally, with care, the molten aluminum will be poured into mould to cool down and then slide out for use.

Advantages of Aluminum Scrap Melting Recycling Induction Furnace: 1, save energy and reduce the environmental temperature Original diesel furnace workshop on pollution, but also the auxiliary exhaust pipeline, inside and outside the furnace heat has a large number of distribution in the workshop, resulting in high temperature workshop. So is the original furnace condition, most escapes to the air, there is heat conduction loss, the production of large power consumption, increase the cost of production. At the same time, the ambient temperature increases. The electromagnetic induction heating process, the heating element is through magnetic field heating, in order to reduce the loss of heat conduction, fast heating, melting rapidly, thus reducing energy consumption. Reduce electricity consumption. After the comparison of the experimental test and modification, the power saving effect is 20%-40%. 2, rapid heating, temperature control accurate real-time Electromagnetic induction heating method is through the magnetic field lines make heating rapid heating, the rapid melting Aluminum Alloy. The temperature control is real-time and accurate, which improves the quality of the product and improves the production efficiency! 3 and long service life, simple maintenance The traditional electric melting induction furnace heating method is to use resistance wire heating, resistance wire in the high temperature environment for a long time in the use of oxidation will result in reducing its service life, high maintenance costs. The electromagnetic heating coil is made of insulating material and high temperature wire, so the service life is long and without any maintenance. 4, power Electromagnetic induction heating with the development and maturity of the technology, the production process and technology of components, software, such as reliable protection of the current power can be 2-200KW. 5, safe The utility model adopts the electromagnetic induction heating, which can reduce the surface temperature of the machine, and the human body can be safely touched, so as to avoid the occurrence of burn and scald accidents caused by the traditional heating mode and protect the production safety of the employees. Features 1 energy saving and environmental protection, Germany's IGBT power devices, high reliability, stable operation and low maintenance costs. 2) the frequency of the digital phase locked loop tracking, automatic load impedance matching. 3 power closed-loop control, to avoid the temperature change caused by the power down. 4) over voltage, under voltage, lack of phase, over current, over heat protection, real-time display of the parameters, fault diagnosis and alarm; leakage automatic alarm, cut off the power supply and the working state of real-time display. 5) PID heating control system, uniform heating temperature, prevent molten aluminum temperature drift, burning less, homogeneous metal components to improve the product qualification rate. 6 (LED) digital temperature controller, measuring and controlling the temperature accuracy of up to 3 degrees centigrade, the quality of aluminum soup is good, the melting temperature rises quickly, the furnace temperature is easy to control, the production efficiency is high; 7) the integral structure of polycrystalline mullite fibers of furnace, small volume, good insulation property, low energy consumption, high efficiency, temperature above 1200 degrees, long service life; 8. The operation is simple and the power can be adjusted with the work; 9 (100%) load duration, maximum power, to ensure the operation of 24 hours. Melting capacity of SMJD series Aluminum Scrap Melting Recycling Induction Furnace:   

Type	Input Power	Melting Capacity			Max Temperature
		steel, stainless steel	copper, gold, silver (scrap, Slag)	aluminum, aluminum alloy, Aluminum scrap, Aluminum slag, pop can	1800℃
SMJD-463	60 KW	200 KG	500 KG	200 KG
SMJD-480	60 KW	150 KG	500 KG	150 KG
SMJD-580	80 KW	200 KG	600 KG	200 KG
SMJD-600	60 KW	230 KG	560 KG	230 KG
SMJD-900	120 KW	300 KG	900 KG	300 KG
SMJD-905	80 KW	300 KG	900 KG	300 KG
SMJD-1250	80 KW	400 KG	1200 KG	400 KG
SMJD-1250	120 KW	450 KG	1350 KG	450 KG
SMJD-1500	120 KW	500 KG	1500 KG	500 KG
SMJD-1550	120 KW	520 KG	1560 KG	520 KG
SMJD-1700	160KW	600 KG	1700 KG	600 KG
SMJD-2300	160KW	800 KG	2000 KG	800 KG
SMJD-3100	200KW	1200 KG	3000 KG	1200 KG

[pdf-embedder url="https://dw-inductionheater.com/wp-content/uploads/2018/10/SMJD-melting-aluminum-furnace-parameter.pdf" title="SMJD melting aluminum furnace parameter"]    

Induction Hot forming and Forging Process

Induction Hot forming is a process in the manufacture of industrial fasteners such as bolts, screws and rivets. Heat is used to soften the metal which is usually a sheet, bar, tube or wire and then pressure is used to alter the shape of the metal by performing any of the following operations: hot heading, blanking, punching, slotting, perforating, trimming, shearing or bending. Besides, billet heating is also a process best performed with induction hot forming. SAMSUNG DIGITAL CAMERAModern induction heating provides many advantages over other heating methods and is commonly used for bonding applications. Heating through induction provides reliable, repeatable, non-contact and energy-efficient heat in a minimal amount of time. Induction heating is also ideal for in-line production processes because of its ability to produce repeatable, rapid and accurate heating cycles. Hot Forming and Forging, hot stamping and extrusion consist of forming a part that has been previously heated to a temperature at which its resistance to deformation is weak. The approximate hot forming temperatures of the most commonly used industrial materials are:

• Steel from 1100 to 1250 ºC
• Brass 750 ºC
• Aluminium 550ºC

After heating up the material, the hot forming operation is done on different types of machines: mechanical impact presses, bending machines, hydraulic extrusion presses, etc. The starting material used in forging is presented in the form of rounded studs, squares (billet) or bar materials. Conventional furnaces (gas, fuel) are used to heat the parts but also induction can be used.

Induction heating advantages:

• Material and energy saving plus flexibility
• Greater quality
• Process control
• Much shorter heating times
• Less oxidise and the production of scale is very low
• Easy and accurate adjustment of the temperature to be applied
• No time needed for the furnace pre and maintenance heating (for example after or during the weekend when it takes more time)
• Automation and reduction of the labour required
• Heat can be directed to one specific point, which is highly important for parts with only one forming area
• Greater thermal efficiency
• Better working conditions as the only heat present in the air is that of the parts themselves

The process of forging and hot forming is a common process in the manufacture of many industrial sectors such as automotive, railway, aerospace, oil and gas, chains and forging.

Induction forging and induction hot forming

Induction forging and induction hot forming refer to the use of an induction heating machine to pre-heat metals prior to deformation using a press or hammer. Typically metals are heated to between 1,100 and 1,200 °C (2,010 and 2,190 °F) to increase their malleability and aid flow in the forging die. Metal induction forging and induction hot forming are excellent induction heating applications. Industrial forging and hot forming processes involve bending or shaping a metal billet or bloom after it has been heated to a temperature at which its resistance to deformation is weak. Blocks of non-ferrous materials can also be used. Induction heating machines or conventional furnaces are used for the initial heating process. Billets can be transported through the inductor via a pneumatic or hydraulic pusher; pinch roller drive; tractor drive; or walking beam. Non-contact pyrometers are used to measure the billet temperature. Other machines such as mechanical impact presses, bending machines, and hydraulic extrusion presses are used to bend or shape the metal. The approximate hot forming temperatures of the most commonly used industrial materials are: • Steel 1200º C • Brass 750º C • Aluminium 550º C

Total Forming Applications

Induction heating machines are commonly used to heat steel billets, bars, brass blocks, and titanium blocks to the proper temperature for forging and hot forming.

Partial Forming Applications

Induction heating is also used to heat parts such as pipe ends, axle ends, automotive parts, and bar ends for partial forming and forging processes.

The Induction Heating Advantage

When compared to conventional furnaces, induction heating machines for forging offer significant process and quality advantages:

• Much shorter heating times, minimizing scaling and oxidation
• Easy and accurate temperature temperature control. Parts at temperatures outside specifications can be detected and removed
• No time lost waiting for the furnace to ramp up to the required temperature
• Automated induction heating machines require minimal manual labor
• Heat can be directed to one specific point, which is highly important for parts with only one forming area.
• Greater thermal efficiency - heat is generated in the part itself and does not need to be heated in a large chamber.
• Better working conditions. The only heat present in the air is that of the parts themselves. The working conditions are much more pleasant than with a fuel furnace.

induction heating steel casting

induction heating steel casting of rubber mold with high frequency induction heater Objective To preheat two irregularly shaped steel castings to be molded and bonded with synthetic rubber Material Two steel castings, 17 lb. irregularly shaped, approximately 6” (152mm) x 9” (229mm) x 1” (25.4mm) Temperature 400 ºF (204 ºC) Frequency 20 kHz Equipment • DW-MF-45kW induction heating system, equipped with a remote workhead containing four 1.0 μF capacitors (for a total of 1.0 μF). • An induction heating coil designed and developed specifically for this application. Process Two steel castings are placed onto an insulated plate with brass guide location pins. The plate is placed onto a table which slides into a large multi-turn helical coil. The parts are induction heated to 400 ºF in 180 seconds. The slow heating time allows the parts to come up to temperature evenly. When the heating cycle is completed each part is placed into a press for the molding and bonding operation. Results/Benefits Induction heating for bulk preheating of steel castings produces: • efficient and repeatable heat vs. a torch or an oven. • even heating of parts throughout Large multi-turn coils provide: • easy loading and unloading of the parts • flexibility for varying bulk castings sizes and geometries

induction heating steel cable for cutting

induction heating steel cable for cutting with radio frequency heating equipment Objective Prior to cutting, heat a short section of a hardened steel cable coated with a polyethylene sheathing. Material Multi-strand braided stainless steel cable 0.5 in. (1.27 cm) OD enclosed within a polyethylene sheathing Temperature 1800 ºF (982) ºC Frequency 240 kHz Equipment • DW-UHF-20kW induction heating system, equipped with a remote workhead containing four (4) 1.0 μF capacitors (for a total of 1.0 μF). • An induction heating coil designed and developed specifically for this application. Process A three-turn helical coil is used to heat the cable in approximately 2 seconds. After the power is turned off, the heat is then transferred to the sheathing. Results/Benefits Induction heating provides a quick, precise repeatable method to reach the high temperature required. It is a very efficient heating method.  

Induction Brazing Steel Parts to Tungsten Carbide Plate

Objective Induction Brazing of Steel Parts to a Tungsten Carbide Plate Equipment DW-UHF-6KW-III handheld induction brazing machine

Test 1 Materials • Steel rod: 19.05 mm (0.75″) OD, 82.55 mm (3.25″) Length • Tungsten Carbide Plate: 38.1 mm (1.5″) OD, 10.16 mm (0.4″) Thickness • Alloy: 19.05 mm (0.75″) Brazing discs Power: 4.0 kW Temperature: Approximately 760° C (1400° F) Time: 40 sec

Test 2 Materials • Steel rod: 12.7 mm (0.50″) OD, 76.2 mm (3″) Length • Tungsten Carbide Plate: 19.05 mm (0.75″) OD, 6.35 mm (0.25″) Thickness • Alloy: 12.7 mm (0.50″) Brazing discs Power: 2.36 kW Temperature: Approximately 760° C (1400° F) Time: 23 sec

Test 3 Materials • Steel rod: 12.7 mm (0.50″) OD, 76.2 mm (3″) Length • Tungsten Carbide Plate: 1″ OD, 1.39mm (0.055″) Thickness • Alloy: 12.7 mm (0.50″) Brazing discs Power: 2.36 kW Temperature: Approximately 760° C (1400° F) Time: 20-25 sec (Pulsing on/off)

Test 4 Materials • Steel rod: 6.35 mm (0.25″) OD, 76.2 mm (3″) Length • Tungsten Carbide Plate: 21.08mm (0.83″) OD, 1.65mm (0.065″) thicknes • Alloy: 6.35 mm (0.25″) Brazing discs Power: 1.96 kW Temperature: Approximately 760° C (1400° F) Time: 20 sec (Pulsing on/off)

Results and Conclusions: Brazing of different steel parts to carbide disks is possible with one induction coil. Power was regulated by turning the heat on and off using a foot switch to prevent overheating of the carbide parts.

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Induction Annealing Copper Wire

Induction Annealing Copper Wire Objective: Induction Annealing a brazing copper wire for preform production. Material: Copper Nickel Silver 2774 Alloy rod 0.070" (1.8mm) diameter. Temperature 650ºF(343.3ºC) Frequency 580 kHz Equipment: • DW-UHF-6kW-III induction heating system equipped with a remote workhead with one 1.0 μF capacitor, and a 4-20 mA input controller to aid in voltage ramping. • An induction heating coil designed and developed specifically for this application. Process A unique helical coil consisting of four consecutive coils connected in parallel with a quartz tube lining is used to heat the wire to 650ºF (343.3ºC) for annealing. Results/Benefits Induction heating provides: • Higher productivity of 27' (8.2m) per minute • Reduction in surface oxidation & scaling • Consistent, repeatable results

Induction Annealing Aluminum PIpe

Induction Annealing Aluminum PIpe With High Frequency Induction Heating Machine Objective Annealing aluminum fuel tank fill neck to 650 ºF (343 ºC) Material Aluminum fill neck 2.5” (63.5mm) diameter, 14” (35.5cm) long Temperature 650 ºF (343 ºC) Frequency 75 kHz Equipment •DW-HF-45kW induction heating system, equipped with a remote workhead containing eight 1.0μF capacitors for a total of 2.0μF • An induction heating coil designed and developed specifically for this application. Process An eight turn helical is used to heat the tube for annealing. To anneal the full length of the tube, the tube is placed in the coil and heated for 30 seconds then rotated and the bottom half is heated for an additional 30. The tube is then bent while hot to prevent cracking. Results/Benefits Induction heating provides: • High efficiency, low energy cost • Fast, controllable and repeatable process • Prevention of cracks • Hands-free heating that involves no operator skill for manufacturing • Even distribution of heating    

How to design induction heating coil

How to design induction heating coil

It is within the induction heating coil/inductor that the varying magnetic field required for induction heating is developed, through the flow of alternating current. Induction heating coil/Inductor design is therefore one of the most important aspects of the overall induction heating machine. A well-designed inductor provides the proper heating pattern for your part and maximizes the efficiency of the induction heating power supply, while still allowing easy insertion and removal of the part. The induction coil/inductor does not have to be shaped in a helix. With the right design, it is possible to heat conductive materials of any size and form, and also possible to heat only the portion of material required. It is even possible to heat different zones of the part at the same or different temperatures by means of a proper design of the inductor geometry. Temperature uniformity within your part is achieved through correct inductor design. The most effective uniformity can be achieved in round parts. Due to the nature of electrical current path flow, parts with sharp edges could preferentially heat in those areas if the proper inductor design is not used.

Coupling Efficiency

There is a proportional relationship between the amount of current flow and distance between the inductor and part. Placing the part close to the inductor increases the flow of current and the amount of heat induced in the part. This relationship is referred to as the coupling efficiency of the inductor.

Basic Construction

Induction heating coil/Inductors are often made of copper tubing - a very good conductor of heat and electricity - with a diameter of 1/8" to 3/16"; larger copper coil assemblies are made for applications such as strip metal heating and pipe heating. Inductors are usually cooled by circulating water, and are most often custom-made to fit the shape and size of the part to be heated. So inductors can have single or multiple turns; have a helical, round or square shape; or be designed as internal (part inside inductor) or external (part adjacent to inductor).

How Induction Heating Coils Work

How efficiently and effectively a workpiece is heated is determined by the induction coil. Induction coils are water-cooled copper conductors created from copper tubing which is readily formed into the shape of the coil for the induction heating process. As water flows through them, induction heating coils themselves do not get hot. Work coils range in complexity from a coil that is precision machined from solid copper and brazed, to a simple solenoid- or helical-wound coil (made up of a number of turns of copper tube wound around a mandrel). By producing an alternating electromagnetic field due to the alternating current flowing in them, coils transfer energy from the power supply to the workpiece. The coil’s alternating electromagnetic field (EMF) creates an induced current (eddy current) in the workpiece, which generates heats due to I Squared R losses (core losses). The coil’s EMF strength correlates with the current in the workpiece. This transfer of energy is known as the eddy current effect or transformer effect.

Brazing carbide shaft with induction

Brazing carbide shaft with induction Objective: Braze a carbide shaft to a steel tube Material: Carbide shaft 1/8" to 1" diameter (varying sizes) Steel tube 3/8" to 1 ¼" OD Silver solder braze Temperature: indicating paint Temperature: 1400 °F for 60 seconds Frequency300 kHz Equipment: DW-UHF-6KW-III, 150-400 kHz solid state induction heating system equipped with a remote heat station containing two 0.66 μF capacitors (total 1.32 μF) A multi-turn helical coil Process: Silver solder is applied to where the carbide shaft and steel tube meet. The clearance between the two parts is approximately .0005". A small piece of solder braze is placed on the part and then the part is heated. It takes about 60 seconds to flow the braze with the best heat migration and solder flow. Even though the part can be heated faster, optimal results are obtained at 60 seconds. Results/Benefits: Induction heating provides even, precise heat. Precise directed heat is required for the solder braze to flow evenly around the part to assure a good joint.

Induction Brazing Carbide To Steel

Objective Induction Brazing carbide to steel parts Equipment DW-HF-15kw Induction Heating Power Supply HLQ custom coil Key Parameters Power: 5.88 kW Temperature: Approximately 1500°F (815°C) Time: 10 sec Materials Coil-  2 helical turns (20 mm ID) 1 planar turn (40 mm OD, 13 mm Height) Carbide-  13 mm OD, 3 mm wall thickness Steel piece– 20 mm OD, 13 mm ID

Process:

1. To demonstrate elimination of “hand feeding” the alloy, we formed the alloy into a ring to tightly fit over the center post tube. This method provides a uniform amount for each cycle, resulting in uniform joints and wetting.
2. The custom made coil was then placed over the steel piece, where is was set for 10 seconds to heat the alloy.
3. The alloy was heated at approximately 1500°F (815)°C
4.  The whole piece is left alone and cooled with ambient air

Results/Benefits:

• Induction Brazing was successful all in under 15 seconds with 8kW
• High quality and repeatability of the brazed joints
• Increased productivity
• Rings will need to be developed for specific joints to prevent the use of too much alloy
• Precise control of the time and temperature

Induction Heat Treating Surface Process

What is induction heat treating surface process?

Induction heating is a heat treating process that allows very targeted heating of metals by electromagnetic induction. The process relies on induced electrical currents within the material to produce heat and is the preferred method used to bond, harden or soften metals or other conductive materials. In modern manufacturing processes, this form of heat treatment offers a beneficial combination of speed, consistency and control. Although the basic principles are well known, modern advances in solid state technology have made the process remarkably simple, cost-effective heating method for applications which involve joining, treating, heating and materials testing. Induction heat treating, through the highly controllable use of an electrically heated coil, will allow you to select the best physical characteristics for not only each metal part—but for each section on that metal part. Induction hardening can impart superior durability to bearing journals and shaft sections without sacrificing the ductility necessary to handle shock loads and vibration. You can harden internal bearing surfaces and valve seats in intricate parts without creating distortion problems. This means that you are able to harden or anneal specific areas for durability and ductility in ways that will best serve your needs.

Benefits of Induction Heat Treating Services

• Focused Heat Treat Surface hardening retains original ductility of core while hardening a high wear area of the part. The hardened area is accurately controlled in respect to case depth, width, location and hardness.
• Optimized Consistency Eliminate the inconsistencies and quality issues associated with open flame, torch heating and other methods. Once the system is properly calibrated and set up, there is no guess work or variation; the heating pattern is repeatable and consistent. With modern solid state systems, precise temperature control provides uniform results.

• Maximized Productivity Production rates can be maximized because heat is developed directly and instantly (>2000º F. in < 1 second) inside the part. Startup is virtually instantaneous; no warm up or cool down cycle is required.
• Improved Product Quality Parts never come into direct contact with a flame or other heating element; the heat is induced within the part itself by alternating electrical current. As a result, product warpage, distortion and reject rates are minimized.
• Reduced Energy Consumption Tired of increasing utility bills? This uniquely energy-efficient process converts up to 90% of the energy expended energy into useful heat; batch furnaces are generally only 45% energy-efficient. No warm-up or cool-down cycles are required so stand-by heat losses are reduced to a bare minimum.
• Environmentally Sound The burning of traditional fossil fuels is unnecessary, resulting in a clean, non-polluting process which will help protect the environment.

What is Induction Heating?

Induction Heating is a Contactless Heating Method of bodies, which absorb energy from an Alternating Magnetic Field, generated by Induction Coil (Inductor). There are two mechanisms of energy absorption:

• generation of close-loop (eddy) currents inside the body which cause heating due to electrical resistance of the body material
• hysteresis heating (for magnetic materials ONLY!) due to a friction of magnetic micro volumes (domains), which rotate following orientation of external magnetic field

Principle of Induction Heating

Chain of phenomena:

• Induction heating power supply delivers current (I1) to induction coil
• Coil currents (ampere-turns) generate magnetic field. Lines of field are always closed (law of nature!) and each line goes around the current source – coil turns and workpiece
• Alternating magnetic field flowing through the part cross-section (coupled to the part) induces voltage in the part

• Induced voltage creates eddy currents (I2) in the part flowing in direction opposite to the coil current where possible
• Eddy currents generate heat in the part

Power Flow in Induction Heating Installations

Alternating current changes direction twice during each frequency cycle. If frequency is 1kHz, current changes direction 2000 times in a second. A product of current and voltage gives the value of instantaneous power (p = i x u), which oscillates between the power supply and the coil. We can say that power is being partially absorbed (Active Power) and partially reflected (Reactive Power) by the coil. Capacitor battery is used to unload the generator from the reactive power. Capacitors receive reactive power from the coil and send it back to the coil supporting oscillations. A circuit “coil-transformer-capacitors” is called Resonant or Tank Circuit.