Search Results for power-supply leads

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.

This article provides a discussion on transformers and reactors for induction heating. It presents information on the initial considerations in the selection process and the demands of power supply and load circuits. The article describes the types of transformers and reactors used in induction heating and maintenance operations. It also provides a discussion on load matching covering the following topics: initial considerations in the load-matching process, understanding the load circuit and the power supply circuit, selecting the desired operating point, adjusting the value of components, and testing the setup.

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.

Plasma arc cutting (PAC) is an erosion process that utilizes a constricted arc in the form of a high-velocity jet of ionized gas to melt and sever metal in a narrow, localized area. This article discusses the process description, equipment, gases, operating sequence, process considerations, and applications of PAC. It concludes with a discussion on the safety measures associated with the PAC process.

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.

In the metal producing and processing industries, induction melting and holding has found wide acceptance. This article provides a detailed account of the physical principles of induction melting processes. It discusses the fundamental principles and components of induction furnaces such as induction crucible furnaces, channel induction furnaces, and induction furnaces with cold crucible. The article describes the advantages, applications, and fundamental principles of induction skull melting. It also provides information on the various specific application-designed induction melting installations.

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.

Cooling towers are designed to remove heat from water in an induction system and dissipate it into the atmosphere. This article provides information on closed-loop recirculating water systems of an induction system to cool the power supply. It focuses on various types of cooling towers, namely, air-cooled heat exchangers, air-cooled heat exchangers with trim cooler, closed-circuit evaporative cooling towers, and open evaporative cooling towers. The article discusses the importance of their placement or positioning to reduce the chances of air recirculation, and concludes with a discussion on refrigerant chillers.

Electromagnetic induction is a way to heat electrically conductive materials such as metals. This article provides a brief history of electromagnetic induction and the development of induction heating technology. It explores various applications such as heating prior to metalworking, heat treating, melting, joining (welding, brazing/soldering, and shrink fitting), coating, paint curing, adhesive bonding, and zone refining of semiconductors. The article also discusses the advantages of induction heating.

This article provides a brief description of load conditions for single-shot heat treating, vertical scanning, and brazing and soldering. It discusses the various power components used in power supplies. These include capacitors, integrated power module, transformers, and various switching devices, namely, silicon-controlled rectifiers, insulated-gate bipolar transistors, and metal-oxide semiconductor field-effect transistors. The article also provides information on frequency-multiplication harmonic-induction power supplies, namely, push-pull and half-bridge inverters and full-bridge inverters. Series resonant and parallel resonant circuits and their tuning calculations associated with output networks are also discussed. The article describes the frequency range of simultaneous dual-frequency induction heating power supply, and discusses the advantages, applications, and technical background of independently controlled frequency and power (IFP) induction heating power supply. It concludes with a description of the developments in control systems for modern induction power supplies.

Electric arc cutting is used on ferrous and nonferrous metals for rough severing, such as removing risers or scrap cutting, as well as for more closely controlled operations. This article describes the operating principles, equipment selection, process variables, and safety measures recommended for plasma arc cutting and air carbon arc cutting. Special applications of electric arc cutting, including shape cutting, gouging, and underwater cutting, are also discussed. The article provides information on other electric arc cutting methods, namely, the exo-process and oxygen arc cutting. It concludes with information on the seldom-used electric arc cutting methods, such as shielded metal arc cutting, gas metal arc cutting, and gas tungsten arc cutting.

Hybrid laser arc welding (HLAW) is a metal joining process that combines laser beam welding (LBW) and arc welding in the same weld pool. This article provides a discussion on the major process variables for two modes of operation of HLAW, namely, stabilization mode and penetration mode. The major process variables for either mode of operation include three sets of welding parameters: the variables for the independent LBW and gas metal arc welding processes and welding variables that are specific to the HLAW process. The article discusses the advantages, limitations, and applications of the HLAW and describes the major components and consumables used for HLAW. The components include the laser source, gas metal arc welding source, hybrid welding head, and motion system. The article also describes the typical sources of defects and safety concerns of HLAW.

This article provides a detailed discussion on the components of a high-performance induction crucible furnace system, namely, furnace body, power supply, and peripheral components. The furnace body contains refractory lining, coil and transformer yokes, and tilting frame and furnace cover. The power supply consists of the following: transformers, frequency converters, capacitor banks, and power cables and furnace coils. The peripheral components comprise recooling device, charging system, and skimming devices. The article also presents a three-dimensional representation of the induction crucible furnace system.

This article discusses the operation principles, advantages, limitations, process parameters, consumables or electrodes, the equipment used, process variations, and safety considerations of gas metal arc welding (GMAW). It reviews the important variables of the GMAW process that affect weld penetration, bead shape, arc stability, productivity, and overall weld quality. These include welding consumables, equipment settings, and gun manipulation. The major components of a GMAW installation such as a welding gun, shielding gas supply, electrode feed unit, power source, and associated controls are discussed.

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.

Melting with induction crucible furnaces (ICFs) is a well-established and reliable technology, and their maintenance must be performed at regularly scheduled intervals to ensure safe operation. This article discusses monitoring of the refractory lining, and presents an overview of the various wear-indication methods, namely, manual checks, ground leakage indication, evaluation of electrical values of the furnace, and temperature measurement. It also presents the working principle, physical restrictions, limitations, and remarks on these methods.

Gas-metal arc welding (GMAW) is an arc welding process that joins metals together by heating them with an electric arc that is established between a consumable electrode (wire) and a workpiece. This article discusses the advantages and limitations, operating principle, metal transfer mechanisms, and process variables of the GMAW process. The process variables include welding current, polarity, arc voltage, travel speed, electrode extension, electrode orientation, and electrode diameter. The major components of the basic equipment for a typical GMAW installation are discussed. The article also describes two consumable elements, such as electrode and shielding gas, of the GMAW process. It concludes with information on the safety aspects.

This article focuses on the process design set-up procedure for brazing and soldering. It provides a detailed account of the types of base metals that can be joined by these processes, and reviews the factors to be considered to enhance the joint design. Criteria for selection of the right induction heating equipment to carry out the brazing or soldering operation are also provided. The article describes the types of brazing filler metals and joint designs. It also presents the types of inspection methods, namely, mechanical and visual, used to determine the quality of the brazed joint. Important considerations for the automation of induction-heated brazing applications are also discussed. The article concludes by emphasizing the need for documenting an in-control process which is a vitally important reference for questions or problems arising in the machine settings or part quality.

The ultrasonic machining (USM) process consists of two methods, namely, ultrasonic impact grinding and rotary USM. This article lists the major ultrasonic components that are similar to both rotary USM and ultrasonic impact grinding. It also provides schematic representations of the components used in rotary USM and ultrasonic impact grinding. The article describes the operations of the components of the rotary ultrasonic machine and ultrasonic impact grinding machine. It discusses the applications of the rotary ultrasonic machine: drilling, milling, and surface grinding. The article concludes with information on machining characteristics of ultrasonic impact grinding.