10 Questions You Should to Know about Custom Induction Heating Equipment

Whether you are acknowledge with induction heating or it’s the first time that you get in touch with this technology, this following article is going to offer some frequently asked questions about induction heating so that help you have a general idea about it.

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What is induction heating?

The heating method known as induction heating occurs when an electrically conductive material is placed in a varying magnetic field. Induction heating is a rapid form of heating in which a current is induced directly into the part being heated. In this way, induction heating is a non-contact form of heating.

Is it possible to braze glass or ceramics with induction?

Yes, of course. If you want to work with glass or ceramics, then a compact vacuum furnace is a great solution for brazing. You’ll get quick, clean heat with very precise temperature control.

What makes up a typical induction heating system?

A typical induction heating system consists of the induction heating power supply, an induction heating coil, and a water-cooling source, which cools the coil and several internal components inside the power supply. The induction heating power supply sends alternating current through the induction coil, thus generating a magnetic field. When a work piece is placed within the coil and enters the magnetic field, eddy currents are induced within the work piece, generating precise and localized heat without any physical contact between the induction coil and the work piece.

What is an 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.

Will induction heating increase my utility bills?

Not likely. Induction heating is a very effective, efficient means of heating. Most of our customers who are switching to induction for the first time see their utility bills go down.

What are typical utility requirements for induction?

Contact us to discuss your requirements of Custom Induction Heating Equipment. Our experienced sales team can help you identify the options that best suit your needs.

Of course it depends on the system, but a typical system requires 220, single-phase VAC or 380, 3-phase VAC at 50/60 Hz. For cooling system, it depends on the capacity of induction heating you choose.

Is this joint suitable for induction brazing?

Our team of metallurgical and mechanical engineers will be glad to have a look at your parts and process to check out and then provide you with the most suitable suggestion for your work. – It’s our pleasure and obligation to do that for you!

Restrictions anywhere in the furnace’s water flow path for the furnace coil can and will cause over-temperature conditions. Restrictions can be caused by debris or calcium buildup in water lines, heat exchanger and water-cooled power cables, internal damage to water-cooled power cables such as “bird nesting”, kinking or flattening of the hose. Water-cooled power cables do fail over time and replacement is required. Life span varies depending on the amount of use, water quality, layout, and configuration. Keep in mind that a restriction is a restriction! It does not matter if it is the feed line, drain line, or coil, all will result in Furnace Drain over-temperature alarm or faults.

The use of an induction melting furnace that was not designed for the application or designed for kW output of the induction power supply, modifying water paths can also cause overtemperature issues.

Furnace lining dimensions and proper installation using quality material is also very important, making changes from original design parameters is not recommended and strongly discouraged. Not having a proper amount of refractory “back-up” material will cause overheating and damage to the furnace coil.

Typically, an internal water high-temperature alarm or fault is caused by flow restriction, either in an individual circuit or a heat exchanger. Power supply cabinets can have multiple circuits and it must be determined which of these circuits are overheating, then determine if it is a flow restriction or other cause for the alarm. A broken switch, signal phase condition is just a couple of possibilities. Flow restrictions are caused by debris in the system, electrolysis, and overall poor water quality.

Induction power supplies typically have an “internal closed-loop” water system or an “external closed-loop” water system, some will have a combination of both. Water purity and quality are critical in both systems for the longevity of the induction melting equipment, minimizing maintenance and costly repairs.

After the system is purged of air and with makeup water functioning, the circulating pump suction side pressure will be 12 – 18 psi, the discharge side of the pump will vary and is dependent on the pump curve and how it was spec’d. When the system is overcharged with water, suction side pressure will be higher 20–30 pounds as well as the discharge side. This does not mean more water is flowing and is detrimental to cooling as it generates heat.

Depending on coil design, configurations and application, the requirements vary widely. Below is an example of how to calculate minimum flow requirements:

1 gallon of water for every 25 kW @ 40 PSI.

Example: An induction melting furnace connected to a 200 kW induction power supply requires a minimum of 8 GPM. 200/25 = 8 or 8 GPM @ 40 PSI. This would be the absolute least amount of water flow to cool and depending on configurations more flow may be required due to higher currents present in the coil.

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