The countless benefits of the induction heating

The process of induction heating is mainly used to transform the physical properties of the metals so that it can be used in a variety of applications. One of the greatest features that are achieved through this form of heating is the flexibility which is more important in today’s business. In order to accomplish different types of production needs, it is necessary to rely on the best systems that can fulfill the requirement as soon as possible. Most of the modern equipments use this concept owing to the innumerable benefits that are associated with it.

Let’s explore the various advantages of the induction heating.

The biggest advantage is that it minimizes the quality issues and make sure that the end result is according to the requirement of the industry. Maintaining the same temperature throughout the process can definitely offer uniform outcomes which are the need of the hour. There is plenty of induction system that comes with brilliant features to make power and heating adjustments as per the need. So it will be better that the industries depend on the advanced systems only.

An increase in the productivity is the next benefit that you can come across. It is because the induction process starts instantly and there is no need to waste time in moving to the manufacturing process. This ensures that a proper flow is maintained and there is no time delay.

Most of the fixtures that are treated with heat can enjoy a long life.  If anything goes wrong with the fixtures, heat can be applied directly to that specific part of the fixture rather than focusing on the complete fixture. In this way, it becomes easy to extend the life of the fixture.

No matter what kind of heating process you are using but emphasis should be on the energy efficient methods only. This helps in higher conversion rate as the heat is utilized in the best possible way. Automated systems usually employ this concept and this is how compatibility is achieved without any complications or difficulties.  Even if there is a small amount of heat loss, it can be balanced easily.

The most important advantage of induction heating is that it is Eco friendly. Such a process has no adverse effect on the environment and that is why it is considered to be the best form of heating the metals too. The process is very safe and emits no smoke or sound that can create a negative effect on the nature.

An introduction to induction heating and its characteristics

The concept of induction heating has been utilized in a number of industrial applications

 and offers a number of advantages as well. But before that it is very necessary to understand what induction heating is all about. It is a way of providing heat to different objects by means of an electromagnetic effect and bond two conductive materials. It has been ages since this concept is being utilized to harden the metals and easily accomplish the manufacturing processes too. Initially this concept was used to harden the metal parts of an engine that was used during the war time. Now the technology has improved thus leading to much advancement in its technique and utility.

Nowadays the induction heating method is quite common and unique too.

The process of heating is induced within the object itself and this is done through high electric currents. Most of the techniques are usually based on the Faraday’s Law, also known as the law of magnetic induction. As per this law, magnetic field is induced when the current is given to the primary transformer while the current is induced only if the secondary transformer is placed in the vicinity of the magnetic field. If one is familiar with this law, it will become really easy to utilize the concept of heat in various industrial applications.

Heating can be conducted only in the case of the metals but it is still possible in the non metals. For this, indirect methods are employed which are simple as well as effective to a great extent. Metals can be brought in contact with nonmetals so that heat is induced within them. Even magnetic materials get heated easily using the concepts of eddy currents. When such materials are heated to a very high temperature, it may lose all its properties and that happens at Curie’s temperature. 

Resistivity is one of the biggest characteristics of induced heating. If you heat two meals of the same size, its results will definitely differ. It is because of the simple reason that metals have different conductivity levels and hence the results can vary. It is important to supply the right amount of heat and power to the metals or the results can be different. The flow of alternating current depends on the magnetic field of the induction heating coil so induction design is also one of the parameters to be considered.  Hence every application requires a subtle combination of various characteristics to reach the results.

What is Magnetic Flux Control?

Magnetic Flux Control Explained

For the purposes of Induction Heating, we can define Magnetic Flux Control as a generic term for the modification of an induction coil's magnetic flux by installing magnetic templates (magnetic flux controllers). Magnetic flux control using the application of non-magnetic entities, such as Faraday rings or flux robbers, are not considered when speaking about induction.

Magnetic Flux Controllers can change magnetic pattern and coil parameters significantly, and when using a controller, their application should be incorporated into the whole induction system design.

Depending on the application, controllers are called a few different names such as:

• Concentrators
• Cores
• Shields

They are given different names because a controller can play different roles such as magnetic flux concentration, shielding, and distribution.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Magneto Dielectric Materials

What exactly are magneto dielectric materials? 

To most of the world, this term doesn’t mean much.  To those of us in the realm of induction heating, magneto dielectrics have very important characteristics that apply themselves to a wide range of possibilities.

MagnetoDielectric Materials are evolving as a material class, and rapid progress is being made on improvements and understanding.  The specific properties of electrical resistivity and anisotropy have not been explored enough to allow for wide use of these materials. Research at the Center for Induction Technology has brought to light the possibility of a wide range of applications.

Essentially, magneto dielectrics are magnetic materials that don't conduct electricity.  Fluxtrol material, with enough voltage, could begin to conduct electricity, but then theoretically so will everything. Essentially, magneto dielectrics are magnetic materials that don't conduct electricity.  

There are essentially three groups of magnetic materials that can be used for magnetic flux control: laminations, ferrites, and MagnetoDielectric Materials, or MDMs.  Laminations are limited in manufacturing and frequency, a fact that is well documented.  Ferrites are used sparingly in induction heating due to their low machinability, sensitivity to thermal shock, and a low saturation flux density. 

MagnetoDielectric Materials are very well suited to fit the requirements of a wide range induction heating applications.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Seven Advantages of Using Magnetic Flux Controllers

In the world of Induction Heating engineers are always trying to make their applications more efficient and more controlled.  Using a magnetic flux controller has many distinct advantages to help us achieve our induction goals.  They are:

1. Very precise heat pattern control
2. The ability to save power or increase production rate due to the increased efficiency and better utilization of power
3. Less current demand for the same amount of power
4. Extended lifetime of the coil
5. Enhancements in power supply performance from higher coil power factor and lower current demand
6. Shielding of the part or machine components from unintended heating
7. Reduction or complete elimination of external magnetic fields, important concerning safety and electromagnetic compatibility issues

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Types of Coils for Surface Heating

There are generally four types of induction heating coils for surface heating.  They are:

1. Inductor with central rod
2. Hairpin
3. Single-turn cylindrical
4. Multi-turn cylindrical

It should be noted as well that a magnetic flux controller will greatly improve induction heating coil performance.  That magnetic flux controller should contain a core and poles for optimum design.  These items are just part of creating an optimal design to achieve peak performance.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Improve Induction Heating Coil with a Magnetic Flux Concentrator

The dramatic difference between a bare induction heating coil versus using a magnetic flux controller is astounding.

In the video below, a coil with a flux concentrator is compared to just a bare coil.  

Flux concentrator material performance is advanced when it is in the best possible thermal contact with the induction coil.  This can be achieved through the use of a uniform and thin layer of a thermally conductive “medium” in–between the contact surfaces. 

 For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Cylindrical Melting Induction Heating Coils

There is a large variety of melting coils, ranging in sizes and designs.  The frequency range is very wide from line frequency for large furnaces to radio frequency for melting of small parts, precious metals, etc.

Big furnaces usually have lamination shunts for parameter improvement, magnetic field shielding and as construction components, while small high and middle frequency furnaces usually have no concentrators or shunts.

Flux controllers may be effectively used in a vacuum or special atmosphere furnaces mainly for shielding purposes.  Coils for melting radioactive materials should be done in a protective atmosphere.  The image below shows a cylindrical coil with a Fluxtrol A shield.  This greatly improves efficiency and power factor and allows for the use of a larger furnace in the same chamber.

 For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Improved Induction Heating Coil Design

It is difficult to make a coil that does not work at all - Anatoly Smimov, old coil master, 1958

Some of us like to say "It's difficult to make a coil that doesn't work, but it's also difficult to make a coil that fits or exceeds modern expectations."

The fact is, magnetic flux control plays a key role in optimal coil design.

Original induction coils for plastic coating applications of stub shafts produced improper temperature distribution and was subject to mechanical damage.

The modern potted coil with a local Fluxtrol controller and stainless steel protective cap provides excellent heat pattern control, improves the mechanical strength of the coil and greatly improves efficiency.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Types of Induction Heating Coils

There are thousands of different induction coil designs with all sorts of different geometries, dimensions and materials used.  Many induction heating coils are created to achieve a simple task and are made in a  shop without any advanced studies and optimization.  Induction coils for "standard" applications (such as scanning coils for shafts and axles) have very significant resources for performance improvement.

The benefits of magnetic flux controllers are typically under-evaluated.  New magnetic materials and advancements in manufacturing technologies give additional opportunities for induction coil design improvement.  Computer simulation is also a very powerful tool for induction coil design and process optimization.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Advanced Induction Coil Design

Induction Heating Coils are essential components of the whole installation and their design and manufacturing quality are extremely important.

Before commencing an advanced induction coil design, a detailed analysis of specifications, available equipment and the environment as well are required. Sometimes, a "design for induction heating"strategy may be applied which includes:

• Modification of heat pattern specifications
• Part geometry modification
• Part Material Change
• Sequence of induction heating operations

Induction Heating coil style and heating process selection must be decided on beforehand, be in scanning, single shot, static, etc. A computer simulation should be run for optimization of the coil head as well as an analysis of the benefits of the magnetic flux controller application.  The coil should be engineered with the design of the coil head, leads, structural components, quenchant supply, etc. all in mind.  

Sometimes advanced manufacturing techniques should be tested in a laboratory or industrial plant to determine performance parameters and to decide if any final corrections may be required.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.

Induction Heating Coil Requirements

Induction Coils are the work tools of Induction Installations

Induction coils must meet specifications of temperature distribution and have good electrical efficiency. Also, they must have a satisfactory life time and provide a desired production rate.  In addition, an induction heating coil must have favorable parameters for efficient energy supply, such as a high impedance and power factor.

In order for a coil to be used in an induction installation, it must have low sensitivity to changes in the part dimensions and positioning in the specified range, all provided at a reasonable cost.  In many cases, magnetic flux controllers are required to achieve these goals.

For more information on Induction Heating, visit the Center for Induction Technology at www.fluxtrol.com.