induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

  https://dw-inductionheater.com/induction-preheating-copper-rod-for-hot-forging.html?feed_id=243393&_unique_id=662dbe6068c8b

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed https://dw-inductionheater.com/induction-preheating-copper-bars.html?feed_id=233983&_unique_id=65cb3208986eb

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

https://dw-inductionheater.com/steel-plate-shovels-hot-forming-with-induction-preheating.html?feed_id=232996&_unique_id=65b4584045c27

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

 

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

  https://dw-inductionheater.com/induction-preheating-copper-rod-for-hot-forging.html?feed_id=226336&_unique_id=64f7185f5f5eb

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed https://dw-inductionheater.com/induction-preheating-copper-bars.html?feed_id=215086&_unique_id=6493b900881b1

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

https://dw-inductionheater.com/steel-plate-shovels-hot-forming-with-induction-preheating.html?feed_id=210436&_unique_id=647cda352040f

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

https://dw-inductionheater.com/steel-plate-shovels-hot-forming-with-induction-preheating.html?feed_id=208636&_unique_id=6473d58721dc8

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment
DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials
• Brass rod
• Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters
Temperature: 780° C
Power: 70 kW
Voltage: 380 – 480 V
Time: 24 sec
Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.


2. The custom Coil was attached to the Heat Station.


3. The Brass rods were placed inside the Coil.


4. The Power Supply was turned on.


5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles


• The process is safer than the flame heating


• Technology without pollution, clean and safe

 

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

 

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

 

steel plate-shovels hot forming with induction preheating

Steel plate-shovels hot forming with induction preheating system

What is induction pre-heating? Induction preheating is a process where materials or workpieces are heated by induction prior to further processing. The reasons for pre-heating vary. In the cable and wire industry, cable cores are pre-heated before insulation extrusion. Steels strips are pre-heated prior to pickling and zinc coating. Induction pre-heating also softens metals before bending, and prepares tubes and pipes for welding. Mobile pre-heating solutions facilitate onsite repairs of bearing assemblies. The induction preheating process is an efficient means of preheating steel plate-shovels for hot forming. This involves bending or shaping a metal billet after being heated to a temperature at which there is less resistance to forming. Induction Heating Objective: A steel shovel manufacturer is looking for an induction heating solution to replace a gas furnace and achieve temperature uniformity, repeatability, and fast heat cycles. Induction Heating Equipment: High Frequency Induction Heater DW-HF-45KW is the recommended induction heating equipment for this induction preheating application. With this induction heating generator, the customer heats the steel shovel molds sustainably and achieves faster heat cycles, especially for the bigger samples. Induction Heating Process: This application aims to preheat 4 steel plate sheets to 1742 F/950 C before posting them in a press to form them as shovels. The goal is for the shovel to reach the desired temperature in less than 5 seconds. Benefits: Implementing induction heating has significant advantages:

• Greater thermal efficiency, resulting in substantial decrease in energy consumption.
• Shorter heating times
• Improved uniformity
• Improved working conditions

https://dw-inductionheater.com/steel-plate-shovels-hot-forming-with-induction-preheating.html?feed_id=162928&_unique_id=635e76e9a20ad

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

 

induction preheating copper rod for hot forging

Induction preheating copper rod for hot forging

In order to want to improve safety and productivity, and reduce energy costs, by using induction instead of resistive heating. To maximize productivity, they want to be able to heat 3 brass rods at a time to 780° C within 25 seconds. For this application test, we are only heating one rod, so our goal is to heat the single rod to 780° C within 25 seconds with less than 45 kW of power. This will ensure that when heating 3 rods, that the 110 kW system will meet the production requirements.

Equipment DW-HF-70kW Induction Heating Power Supply, operating between 10-50 kHz

Materials • Brass rod • Custom coil, 10 turns, D=50mm, designed and manufactured by DaWei Induction Power Technologies for this specific application – capable to heat 3 rods at a heat cycle.

Key Parameters Temperature: 780° C Power: 70 kW Voltage: 380 – 480 V Time: 24 sec Frequency: 32 kHz

Process:

1. The DW-HF series Power Supply was connected to the DW-HF-70kw Heat Station.
2. The custom Coil was attached to the Heat Station.
3. The Brass rods were placed inside the Coil.
4. The Power Supply was turned on.
5. The DW-HF series operating at 20 kW was able to successfully heat the single brass rod within 24 seconds, which was less than the 25 second time requirement established for the test. Three brass rods are expected then to heat within 25 seconds with approximately 60 kW of power (3 rods will be 3x the load and 3x the power). The 90 kW Induction system will therefore meet the customer’s requirements.

Results/Benefits:

Induction preheating provides:

• Faster heating cycles
• The process is safer than the flame heating
• Technology without pollution, clean and safe

 

induction preheating copper bars

induction preheating copper bars to temperature

Objective: To preheat two copper bars to temperature within 30 seconds; the client is looking to replace a competitor’s 5kW induction heating system that is delivering unsatisfactory results Material:  Copper bars (1.25” x 0.375” x 3.5”/31mm x 10mm x 89mm ) - Thermal indicating paint Temperature: 750 ºF (399 ºC) Frequency: 61 kHz Equipment : DW-HF- 15kW, 50-150 kHz induction heating power supply with a remote workhead containing two 1.0 μF capacitors - A dual-position, multi-turn helical coil designed and developed for this heating application Induction Heating Process: A thermal indicating paint was applied to the face of the copper bar, and the bar was placed inside the coil. The part was heated for 30 seconds and it reached temperature. The next step in the process was to heat two parts in a dual-position coil. The parts were inserted into the coil and heated to temperature within 30 seconds. In order to heat four parts to temperature within the same time period, two power supplies and two dual-position coils are required. Results/Benefits -- Speed: Induction was able to meet their time requirements. -- Process development: The HLQ lab team was able to help the client develop a new heating process that achieved better results than what they saw with their old, inferior induction heating system -- Process efficiency: With induction and the right induction partner, a time, energy and space efficient system was designed