Energy Saving Induction Heating Equipment For Shaft Quenching, Gear
Hardening
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What is induction heating?
Induction heating is a process which is used to bond, harden or
soften metals or other conductive materials. For many modern
manufacturing processes, induction heating offers an attractive
combination of speed, consistency and control.
How Induction Heating Works?
When an alternating electrical current is applied to the primary of
a transformer, an alternating magnetic field is created. According
to Faraday's Law, if the secondary of the transformer is located within the
magnetic field, an electric current will be induced.
In a basic induction heating setup shown in the following pic, a solid state RF power supply sends an AC current through an
inductor (often a copper coil),and the part to be heated (the
workpiece) is placed inside the inductor. The inductor serves as
the transformer primary and the part to be heated becomes a short
circuit secondary. When a metal part is placed within the inductor
and enters the magnetic field, circulating eddy currents are
induced within the part.
As shown in following pictuer, these eddy currents flow against the
electrical resistivity of the metal, generating precise and
localized heat without any direct contact between the part and the
inductor. This heating occurs with both magnetic and non-magnetic
parts, and is often referred to as the "Joule effect", referring to
Joule's first law – a scientific formula expressing the
relationship between heat produced by electrical current passed
through a conductor.
Secondarily, additional heat is produced within magnetic parts
through hysteresis – internal friction that is created when
magnetic parts pass through the inductor. Magnetic materials
naturally offer electrical resistance to the rapidly changing
magnetic fields within the inductor. This resistance produces
internal friction which in turn produces heat.
In the process of heating the material, there is therefore no
contact between the inductor and the part, and neither are there
any combustion gases. The material to be heated can be located in a
setting isolated from the power supply; submerged in a liquid,
covered by isolated substances, in gaseous atmospheres or even in a
vacuum.
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Induction Heater Power Require depends on following factors : |
» | Mass of work piece | » | Material properties of work piece |
» | Temperature increase you require | » | Heating time require |
» | Effectiveness of coil design | » | Comprehensive full load design |
» | Any heat loss during heating process |
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The parameters of the Fast Heating Industrial Induction Heating Machine GYSQ-TC-120AB:
Model | GYSQ-TC -120AB (Three phase) |
work power | 340V-430V |
Maximum input current | 180A |
Output power | 120KW |
fluctuating frequency | 10-50khz |
output current | 400-4000A |
the flow rate of cooling water | 0.08-0.16Mpa 10L/Min |
water temperature protection point | 50C |
product size | main : 770x550x1510mm |
transformer : 870x430x750 mm |
net weight | main : 150gks |
transformer : 120kgs |
Delivery Time: within 7 workdays.
Shipping Term:By sea,By air,by express.
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THE ADVANTAGES OF THE INDUCTION HEATER:
Optimized Consistency
- Induction heating eliminates 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; power can be instantly turned on
or shut off. With closed loop temperature control, advanced
induction heating systems have the capability to measure the
temperature of each individual part. Specific ramp up, hold and
ramp down rates can be established & data can be recorded for
each part that is run.
Maximized Productivity
- Production rates can be maximized because induction works so
quickly; 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. The induction heating
process can be completed on the manufacturing floor, next to the
cold or hot forming machine, instead of sending batches of parts to
a remote furnace area or subcontractor. For example, a brazing or
soldering process which previously required a time-consuming,
off-line batch heating approach can now be replaced with a
continuous, one-piece flow manufacturing system.
Improved Product Quality
- With induction, the part to be heated never comes 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.
The vacuum brazing process is often utilized when maximum product
quality is essential; the part can be isolated in an enclosed
chamber with a vacuum, inert or reducing atmosphere to eliminate
the effects of oxidation.
Extended Fixture Life
- Induction heating rapidly delivers site-specific heat to very small
areas of your part, without heating any surrounding parts. This
extends the life of the fixturing and mechanical setup.
Environmentally Sound
- Induction heating systems do not burn traditional fossil fuels;
induction is a clean, non-polluting process which will help protect
the environment. An induction system improves working conditions
for your employees by eliminating smoke, waste heat, noxious
emissions and loud noise. Heating is safe and efficient with no
open flame to endanger the operator or obscure the process.
Non-conductive materials are not affected and can be located in
close proximity to the heating zone without damage.
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. And since induction requires no warm-up or
cool-down cycle, stand-by heat losses are reduced to a bare
minimum. The repeatability and consistency of the induction process
make it highly compatible with energy-efficient automated systems.
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![GEAR HARDENING](http://img.everychina.com/nimg/6c/c0/a33496769a3ccadaab2e422dc92b.jpg)
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Our services
Pre-sale service.
- Inquiry and consulting service
- Recommend the most suitable for our customers according to their
requirements
- Sample testing support
- Working videos available
- View our factory
In-sale service.
- Strictly manufacture the machine, according to relevant
technical standards.
- Take run test, according to relevant equipment test run
regulations.
- Strictly check up the machine, before delivery
- Delivery on time.
After-sale service.
- Warranty time: 1year Warranty.
- Within warranty all parts are free for customer, any fault
caused by non-artificial reason, any quality problems such as
design, manufacture, or procedure occurs, We shall provide
replacement parts after detecting the faults.
- If any big quality problems occurs out of the guarantee
period, we will send maintenance
- Technician to provide visiting service after checking with the
customer and charge for a favorable price.
- We will provide a lifetime cost price to the buyer with the
materials and spare parts used in system operation, equipment
maintenance.
- The above mentioned are only basic aftersale service
requirements,we will make more promises related to quality
assurance and operation guarantee.