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CEIA InductionHeatingPrinciples FC040K0068v1uk PDF
CEIA InductionHeatingPrinciples FC040K0068v1uk PDF
Principles
PRESENTATION
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Main Applications of Induction Heating
Hard (Silver) Brazing
Tin Soldering
Heat Treatment
(Hardening, Annealing, Tempering, )
Forging
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Examples of
induction heating applications
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Advantages of Induction
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Basics of Induction
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Basics of induction
The heating occurs without physical contact, it involves
only the metal parts to be treated and it is characterized
by a high efficiency transfer without loss of heat.
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Basics of Induction
The phenomenon of the electromagnetic induction is
therefore based on three physical principles, here below
explained:
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Useful Equations
1) Transfer of energy from the inductor to the mass to be heated, by means of
Electromagnetic Fields.
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If the conductor has a solenoid shape, the magnetic filed generated has
the shape as in the pictures below:
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The Laplace Law states that the intensity of the magnetic field is reverse proportional to the square of the
distance.
In case of a single loop coil, the intensity of the magnetic flow at the point P, whose distance from the coil center is z,
Is given by the simplified equation:
35
Magnetic Field intensity vs. Coil distance
30
Coil = 15mm
25
B [mT]
20
15
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
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FaradayLenzs Law
These circulating eddy current create induced magnetic fields that oppose
the change of the original magnetic field due to Lenz laws, causing
repulsive or drag forces between the conductor and the magnet.
The stronger the applied magnetic field, or the greater the electrical
Coil conductivity of the conductor, or the faster the field that the
conductor is exposed to changes, then the greater the currents that
are developed.
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Electro Magnetic Features of Metals
The magnetic permeability of a material is the capability of this material to channel magnetic induction.
In fact, magnetic field H and magnetic induction field B are linked, in a given material, by the equation :
B=*H
where is the magnetic permeability of the material (in Henry/meter). =0 * r
- 0 is a universal constant, equal to -7 H/m
- r depends on the material.
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2) Transformation of the electric energy into heat due to Joule Effect.
Z)
Material C ^C
Silver 1.5910 6.30107
Copper 1.6810 5.96107
Gold 2.4410 4.52107
Aluminium 2.8210 3.5107
Tungsten 5.6010 1.79107
Iron 1.010 1.00107
Platinum 1.0610 9.43106
Tin 1.0910 9.17106
Titanium 4.20x10 2.38106
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Skin Effect
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Skin Depth Calculation
Calculation of skin depth at different frequency for magnetic and not-magnetic material
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Skin depth versus frequency
1.000,00
10,00
Skin depth [mm]
1,00
0,10
0,01
0,00
1 10 100 1.000 10.000 100.000 1.000.000
Frequency [Hz]
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3) Transmission of the heat inside the mass by means of Thermal Conduction.
The law of Heat Conduction, also known as Fouriers law, states that the time rate of
heat transfer through a material is proportional to the negative gradient in the
temperature and to the area through which the heat is flowing.
Material Thermal
conductivity
t<
Stainless Steel 16
Carbon Steel 36
Brass 109
Aluminum 205
Copper 385
Silver 406
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Structure and Hystory of Inductive Heating Generators
Work Head
This contains a combination of capacitors and transformers and it is used to match the power unit to the
work coil
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CLASSIC Structure
Valve Oscillator Generator (1970-1990)
Problems:
- Output power instability
The output power is affected by power supply voltage fluctuation, and the generator
is not able to follow the set power in case of load variation (i.e. heating over Curie Point)
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Conventional Structure (1990 Today)
Solid State Transistor Generators
Nowadays the use of MOSFET or IGBT transistors has replaced the use vacuum valves, and is become
the heart of all conventional inductive heating generators in the market.
Main Features:
- Overall dimensions smaller then valve generators
- Higher efficiency
- Higher working frequency range
Problems:
- High current flow from generator to Heating Head
- Output power instability in case of mains voltage fluctuation, or load variation
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CEIA Induction Heating Generators
Main Features and Difference vs. conventional generators
- Real-Time Micro processor control of the power generation
- Extremely compact design
- Coil voltage feedback sensors
- Resonant Heating Head (low current flow from generator to heating head)
- Maintains stable output power even as working conditions change (calibration report)
- Specific Control unit for output power control
- EMC and CE certified
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The CEIA inductive heating system allows to a very fast and accurate temperature control.
They are suitable for industrial and automatic process , they are installed also on robotic
system where is required:
No Tolerance Admitted
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Heating Head Structure
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Heating Head Structure
R load
The coil shape and the gap between coil and sample
is extremely important in order to maximize the
power transfer
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Heating Head and Sample to be heated: Equivalent Circuit
C1= Heating Head Capacity (&)
L1= Coil Inductivity (,)
Z
Z^
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Types of Heating Coils
Open Shape coil
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Example of induction heating applications
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Thank you for your attention
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