Search Results for induction coil design

This article is a compilation of best practices, materials, and techniques for the design and manufacture of modern induction forge coils. It presents the basics of induction coil design along with various design considerations, namely, copper tube selection, water flow considerations, and brazing and fabricating the copper coil winding for heating billets, bars, and slabs. The article describes refractory selection criteria and the methods of mounting and securing the induction coil winding, and presents general refractory installation guidelines for induction heating applications. It provides information on curing, form removal, dryout, and coil refractory seasoning. Wear rails that are designed to prevent damage to the coil refractory and subsequent coil winding are also discussed. The article concludes with a discussion on preventive maintenance practices for induction forging coils.

This article provides information on single-shot and scanning, the two types of induction heat treating processes that are based on whether the induction coil is moving relative to the part during the heating process. It describes the effect of the frequency of induction heating current on the induction coil and process design, and the control of heating in different areas of the inductor part. The article reviews three main tools for adjustment of coil design and fabrication: coupling gap, coil copper profile, and magnetic flux controllers. It examines the method of holding a part and presenting it to the inductor during the initial inductor design. The article provides information on coil leads/busswork and contacts that mechanically and electrically connect the induction coil head to the power supply. It concludes with a discussion on flux and oxide removal, leak and flow checking, silver plating, and electrical parameter measurement.

Magnetic flux controllers are materials other than the copper coil that are used in induction systems to alter the flow of the magnetic field. This article describes the effects of magnetic flux controllers on common coil styles, namely, outer diameter coils, inner diameter coils, and linear coils. It provides information on the role of magnetic flux controllers for whole-body and local area mass-heating applications, continuous induction tube welding, seam-annealing inductors, and various induction melting systems, namely, channel-type, crucible-type, and cold crucible systems. The article also describes the benefits of the flux controllers for induction heat treating processes such as single-shot and scanning.

Induction heating has many different applications, such as melting, heating stock for forging, and heat treating. This article begins with a discussion on the types of power supplies, namely, solid-state power supplies and oscillator tubes. It provides information on system elements, including cooling systems, power supplies, heat stations, work handling fixtures, induction or work coils, and quench systems. The article discusses the influence of system elements on induction heat treating system design. It also deals with the general theory, types, and applications of induction coils.

Inductors used for brazing can be machined from solid copper shapes or fabricated out of copper tubing, depending on the size and complexity of the braze joint geometry to be heated. This article provides information on inductors (coils) that are generally classified as solenoid, channel (slot), pancake, hairpin, butterfly, split-return, or internal coils. It discusses the variables pertinent to the design of inductors for brazing, soldering, or heat treating. The article presents various considerations for designing inductors for brazing of dissimilar materials that present a unique challenge in the field of induction brazing.

This article focuses on the frequently encountered causes of induction coil failures and typical failure modes in fabrication of hardening inductors, tooth-by-tooth gear-hardening inductors, clamshell inductors, contactless inductors, split-return inductors, butterfly inductors, and inductors for heating internal surfaces. It discusses the current density distribution and the skin effect, the proximity effect, and crack-propagation specifics. The article also describes selected properties of copper alloys, the electromagnetic edge effect of coil copper turn, and the effect of magnetic flux concentrators on coil life. It also reviews the importance of having appropriate and reliable electrical contacts.

This article begins with a discussion on the principle of induction brazing and addresses applications, advantages, and limitations of the process. It provides information on the induction brazing equipment and solid-state induction generators that are used in induction brazing. The article illustrates several basic joint designs for induction brazing as well as typical coils and some frequent applications and lists joint parameters for parts which are to be brazed by induction heating. It concludes with a discussion on the effect of thermal expansion on stress in the joint.

This article provides a rough estimate of the basic parameters, including coil efficiency, power, and frequency in induction heating of billets, rods, and bars. It focuses on the frequency selection for heating solid cylinders made of nonmagnetic metals, frequency selection when heating solid cylinders made from nonmagnetic alloys, and frequency selection when heating solid cylinders made from magnetic alloys. The article describes several design concepts that can be used for induction billet heating, namely, static heating and progressive/continuous heating. It presents the four major factors associated with the location and magnitude of subsurface overheating: frequency, refractory, final temperature, and power distribution along the heating line. The article summarizes the pros and cons of using a single power supply. It also reviews the design features of modular systems, and concludes with information on the temperature profile modeling software.

The handling of billets or bars is an essential part of an induction heating system. This article describes two types of handling systems available for bar heating lines: inclined ramps with escapement, and sling feeder with inclined ramp and escapement. It focuses on the various infeed billet handling systems such as bin tippers, elevator feeders, rotary feeders, vibratory bowl feeders, magazine loaders, and rod feeders. The article provides information on the main categories of billet feeding systems, namely, dual pinch roll drive assemblies, tractor drive assemblies, billet pusher systems, walking beam assemblies, and index/continuous conveyor systems. It also discussed the hot billet handling systems used to deliver heated billets to the forging cell. These methods include billet extractor conveyors, accept/reject systems with pyrometer measurements, extractor rolls, discharge chutes, pinch roll extractors, pick-n-place systems, and robots.

Induction heating system control is straightforward after the design and application of the coil and power supply required for the job. This article provides an overview of the basic components of an induction heating system, including a machine controller (computer or programmable logic controller), interface wiring, an operator interface, and safety controls. It also provides information on programming devices and temperature controllers, such as manual, auto, and auto-manual temperature controllers.

This article discusses the principle, coil design, types and operation of a vacuum induction furnace. It describes the operation parameters that should be considered during the functioning of the induction furnace.