Are Induction Heating Machines the Best Solution for any Industry?

Verifying that you are not a robot...

A can of peaches, a cruise liner’s hull, a tub of yogurt, power station turbines, cables under the ground, pipelines under the waves, and countless trains, planes, and automobiles. What unites these different products is that induction heating is used to make them, maintain them, repair them, and recycle them. (In case the yogurt tub intrigues you, induction heating attaches the foil lid to the plastic container. As for canned peaches, induction heating helps coat the tin on the can’s inside so that conserved foods remain untainted.) 
Every day, across every continent, induction heating is used to improve our lives. Just take the manufacture of an average family car for example. Induction is used for hardening camshafts, crankshafts, gears and steering parts. It bonds doors, boots and bonnets and joins the pipes in the air-conditioning system. Induction heating is used to make everything from faucets to spaceships. Simply put, induction heating solutions can be profitably used in virtually any industrial application that requires heat.

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We think that's pretty amazing. 

How much energy do you need?

Before calculating your energy requirements you first need to know:

• The type of material (steel, copper, brass, etc.)

• Workpiece dimensions

• Desired hourly production

• Desired final temperature

Calculate your energy requirements

Step 1 First determine the material’s energy absorption rate. Fig. 1 shows rates for some common materials.


Step 2 Multiply the energy absorption rate by your desired hourly production (kg/hour). The result is your specific power requirement.


Step 3 You can now ascertain the overall efficiency level of the induction equipment. Some typical induction heater efficiency levels for common materials are listed in Fig. 2. Divide the calculated specific power need by the equipment efficiency rate. This gives you the total power requirement.

The induction coil (also known as ‘inductor’, or ‘coil’), is one of the most important components in an induction heating system. It is also one of the most neglected and misunderstood.The problem is that too many people see the coil as little more than a copper tube through which cooling water and an alternating current are fed. But nothing could be further from the truth. In fact, a correctly designed and professionally made coil has a decisive impact in several areas. 

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Correct process outcomes

The heating patterns, temperatures and heat penetration depths achieved during an induction heating cycle are directly and profoundly influenced by the coil’s physical characteristics. A poorly designed or manufactured coil yields poor results.

Cost control

A professionally designed and manufactured coil that is properly maintained has a much longer and more productive working life than its amateurish counter parts. Also, a correctly built and maintained coil helps minimize waste.

Overall system efficiency

ENRX induction heating systems are designed to operate with ENRX coils. Using the correct coils means significant long-term savings.

A crash course in coils

Designing and making induction coils is not easy. Here are just three of the many challenges that need to be overcome in order to make safe, efficient coils.

Through-flow rate

It is critical to achieve adequate flow of cooling water through the coil. This is especially true with high-power density coils, as low through-flow results in insufficient thermal transference. A booster pump may also be needed to maintain the desired flow. Good designers specify a purity level for the water, in order to minimize corrosion on the inside of the coil.

Magnetic flux concentrators

Concentrators focus the current in the coil area facing the workpiece. Without them, much of the magnetic flux may propagate around the coil. This flux could engulf adjacent conductive components. But, when concentrated, the flux is restricted to precise areas of the workpiece. Concentrators are made from laminations, or from pure ferrites and ferrite- or iron-based powders. Each material has its own pros and cons.

•  Laminations have the highest flux densities and magnetic permeability, and are less expensive than iron- and ferrite-based powders. Laminations are however stamped to a few standardized sizes and are therefore less flexible. They are also labour intensive to mount.
• Pure ferrites can provide outstanding magnetic permeability. But they suffer from low saturation flux density, and their brittleness makes them difficult to machine.
• Iron powders are easy to shape, offer high flux densities, and are easy to shape. However, care must be taken to protect against overheating, as internal losses or heat transfer from the heated workpiece mean such powders have a relatively low working temperature.

Impedance matching

It is necessary to achieve the correct impedance matching between the coil and the power source in order to use the latter’s full power. The designer must also consider that coils need five to ten times as much reactive as active power.