You can make an induction heater yourself if you approach this process correctlyInduction heating- This modern way heat treatment electrically conductive substances and materials that have the most high coefficient useful action among existing methods. For more economical operation of heating and household appliances Today, special induction heaters are used. How they work induction devices and how to make an induction heating apparatus yourself - read below.
- What is induction heating: advantages
- Vortex Induction Heater
- Induction heater circuit based on printed circuit board
- The simplest DIY induction heater
- How to make an induction heater with your own hands: instructions
- Induction heater from welding inverter: peculiarities
- What is an induction heater (video)
The principle of induction heating is based on the influence alternating current on the transformer winding and the subsequent occurrence of electrical magnetic field. As a result of the occurrence of a magnetic field, an electric current is generated between magnetic and non-magnetic parts. It is high-frequency currents (HFC) that heat various electrically conductive materials.
The advantage of an induction heater is that it is lightweight
Induction heating has many advantages:
- The induction heating device is lightweight, so it can be easily used for domestic purposes;
- Induction heating is ideal for all types of heat treatment of metal, among which welding, soldering, and forging are especially popular;
- High-frequency heating can be carried out in a vacuum, protective gas;
- Using induction, you can quickly and evenly heat electrically conductive substances and obtain ultra-pure metals.
In addition, this heating method is extremely economical: it converts up to 90% of the consumed energy into heat (despite the fact that conventional electric heaters have, on average, 45-50%).
Vortex Induction Heater
Due to its economic benefits, induction heating is widely used today. The vortex induction heating device is perfect for rooms up to 60 square meters. m, which must be heated with electricity. Thus, VIN can be used for heating private houses, industrial and storage facilities, gas stations, car service centers and other free-standing facilities.
The vortex induction heater is quite popular.
The main advantages of using VIN as the “heart” of the heating system include the following:
- Heating occurs almost instantly, because heat occurs directly in the part;
- Over the years, the installation operates with the same power, its productivity does not decrease;
- Compared with conventional electric heating elements, the induction vortex device saves up to 50% of electricity.
That is why today, more and more companies producing household appliances and production machines use induction heating. An example of such use, in addition to heating boilers, is an induction electric furnace. Ultrasonic induction heater is used in the food industry. For heating metals in industry, an inverter induction apparatus is used, for melting non-ferrous metals - a melting-reduction unit, forging iron and making blanks - an induction electric forge.
Circuit board based induction heater circuit
You can make a VIN with your own hands. In order to correctly assemble a vortex induction heating apparatus, it is necessary to find a diagram of the device. The simplest is a printed circuit board circuit, which is a chopper operating on high-power transistors.
The characteristic differences of this scheme are:
- Heating inductor (coil) in the form of a spiral with 6-8 turns;
- The presence of a voltage regulator (can be taken from an old computer unit);
- The presence of a resistance that protects the transistors from overheating.
Before making an induction heater for a printed circuit board, you should first familiarize yourself with its diagram
It is recommended to install transistors in a heater assembled according to this scheme on special radiators: this will avoid overheating of the device. Using the same scheme, you can assemble an induction water heater.
The vortex induction heater device includes:
- Coil;
- Heat exchanger;
- Terminal box;
- Control cabinet;
- Inlet and outlet pipes.
This circuit is based on the resonant principle of operation occurring in a series oscillatory circuit. The magnetic flux between the turns of the coil is closed through the air.
To assemble a heater for water heating, the easiest way is to use a circuit with a transformer consisting of primary and secondary short-circuited windings. The water will be heated by passing through the pipes inside the coil and supplied heated from the outlet pipe.
At the same time, it should be remembered that in water heating systems with VID it is necessary to use a pump for forced circulation water.
If it is not possible to install a flow pump, then you can choose a mechanical heater for liquid coolant as a heating element or attach a permanent magnet heater to the wall of the coolant tank.
The simplest DIY induction heater
The most budget induction generator can be done by taking a transformer magnetic core. A fairly powerful device for induction heating can be assembled from an electronic transformer, which is a switching power supply.
In order to assemble a simple induction heater, you need to prepare tools for work
In order to assemble the device you need:
- Solder the main transformer from the electrical one;
- Make an inductor based on a ferrite cup;
- Solder the ends of the wires into place pulse block nutrition.
Such a heater will have an efficiency of at least 65%. This will be enough to assemble a small induction electric oven. In addition, with the help of such a device it will be possible to quickly melt wires with a diameter of up to 4 mm.
How to make an induction heater with your own hands: instructions
An induction heating apparatus can be made from an inverter power source welding machine. At the same time, the design can be simplified by placing a straight pipe inside the induction coil. It will work as a core. In order to make a heater you will need: polymer pipe diameter 5 cm; steel wire with a diameter of 0.6 cm; copper wire by 3mm; construction metal fine mesh.
Before making an induction heater, you can additionally read the detailed instructions
Let's get started:
- We cut the wire rod into pieces 3-6 mm long;
- We cover one end of the pipe with a construction mesh;
- We put pieces of wire inside the pipe;
- Cover the second end of the pipe with mesh;
- We make a winding on top of the pipe (turns should be at least 85 and no more than 95);
- We insulate the ends of the winding and connect them to the output of one of the types of welding arc power source.
The device is ready! Now, during operation of the device, the coil will create an electromagnetic field and eddy current flows. This will cause the device to heat up quickly.
Induction heater from a welding inverter: features
IN in the usual form induction heaters made from a welding inverter pose an increased danger, because they cannot autonomously control the water temperature. Thus, using a heater in systems with coolant can be fraught with short circuits and pipe rupture. This can occur due to high hydraulic resistance in the system, which occurs due to the movement of coolant through pieces of wire rod. Therefore, such devices require improvements.
An induction heater made from a welding inverter is practical and of high quality.
To avoid emergency situations, you should supply homemade apparatus induction heating, made from a welding inverter, emergency shutdown devices.
To control heating, you can use a thermostat with a temperature sensor and a relay that opens the circuit when the coolant temperature reaches the set values. In addition, it will be possible to avoid rupture of the system by attaching a safety valve to the heater through a tee, on one side.
Experienced electricians say that converting one type of welding arc power source into a heater is not justified: thermal power heater will limit electric power inverter
Such a heat generator is enough to heat a room whose area is no more than 30 square meters. m. Cost savings, in this case, will be 30-50% (depending on the size of the apartment). At the same time, you will lose your expensive welding machine today.
What is an induction heater (video)
Inductive heating is a modern method of heat treatment of electrically conductive substances, which has found wide acceptance household use. Thus, vortex induction heaters are excellent for organizing more economical and efficient work heating system. You can make an induction generator yourself. The main thing is to take into account the recommendations of professional electricians and carry out all work consistently!
An induction heater allows you to heat metal until it turns red without even touching it. The basis of such a heater is a coil in which a field is created high frequency, which acts on a metal object placed inside. Current is induced in the metal high density, which causes the metal to heat up. Thus, to create an induction heater you will need a circuit that generates high-frequency oscillations and the coil itself.
Scheme
Above is a diagram of a universal ZVS driver, which is based on powerful field-effect transistors. It is best to use IRFP260, rated for a current of more than 40 A, but if you cannot get these, you can use IRFP250, they are also suitable for this circuit. D1 and D2 are zener diodes, you can use any voltage from 12 to 16 volts. D3 and D4, ultra-fast diodes, can be used, for example, SF18 or UF4007. It is advisable to take resistors R3 and R4 with a power of 3-5 watts, otherwise they may heat up. L1 – inductor, can be taken in the range of 10-200 µH. It must be wound with a sufficiently thick copper wire, otherwise heating cannot be avoided. Making it yourself is very simple - just wind 20-30 turns of wire with a cross-section of 0.7-1 mm on any ferrite ring. Special attention It is worth paying attention to capacitor C1 - it must be designed for a voltage of at least 250 volts. Capacitance can vary from 0.250 to 1 µF. A large current will flow through this capacitor, so it must be massive, otherwise it will heat up. L2 and L3 are the same coil inside which the heated object is placed. It consists of 6-10 turns of thick copper wire on a mandrel with a diameter of 2-3 centimeters. You need to make a tap on the coil from the middle and connect it to coil L1.
(downloads: 481)
Heater circuit assembly
The circuit is assembled on a piece of PCB measuring 60x40 mm. The printed circuit board design is completely ready for printing and does not need to be mirrored. The board is made using the LUT method; below are several photographs of the process.
After drilling the holes, the board must be tinned with a thick layer of solder for better conductivity of the tracks, because large currents will flow through them. As usual, small parts, diodes, zener diodes and 10 kOhm resistors are soldered first. Powerful 470 Ohm resistors are installed on the board while standing to save space. To connect the power wires, you can use a terminal block; there is a place for it on the board. After soldering all the parts, you need to wash off the remaining flux and check the adjacent tracks for short circuits.
Making an induction coil
The coil consists of 6-10 turns of thick copper wire on a mandrel with a diameter of 2-3 centimeters; the mandrel must be dielectric. If the wire holds its shape well, you can do without it altogether. I used regular 1.5mm wire and wound it around a piece of plastic pipe. Electrical tape works well for fastening the turns.
A tap is made from the middle of the coil; you can simply remove the insulation from the wire and solder a third wire there, as I did. All wires must have a large cross-section to avoid unnecessary losses.
First launch and testing of the heater
The supply voltage of the circuit is in the range of 12-35 volts. The higher the voltage, the more the metal object heats up. But at the same time, the heat dissipation on the transistors increases - if with a power supply of 12 volts they hardly heat up, then at 30 volts they may already require a radiator with active cooling. You should also monitor capacitor C1 - if it heats up noticeably, then you should take a higher voltage one, or assemble a battery of several capacitors. When starting up for the first time, you will need an ammeter connected to the break in one of the supply wires. On Idling, i.e. With no metal object inside the coil, the circuit draws about 0.5 amps. If the current is normal, you can place a metal object inside the coil and watch it heat up literally before your eyes. Happy assembly.Today, induction heat generators are used quite widely. Compared to traditional heating boilers, they are characterized by higher efficiency. In addition, the use of an induction water heater allows you to reduce energy costs. Since the factory models of units of this type have high cost, owners of private houses often decide to assemble the device themselves.
Operating principle
The idea to make homemade water heater the induction type seems very attractive. Such a unit is practically not inferior in efficiency to factory models, but will cost the home owner significantly less. To make an induction heater with your own hands, You will need three main elements:
- Generator.
- A heating element.
- Inductor.
A generator is needed to obtain high frequency alternating current from a standard home network. A coil made of copper wire. The task of this structural element is to generate a magnetic field. A metal object is used to make a heater, capable of absorbing heat energy under the influence of a magnetic field.
Simple DIY induction heater
If all these elements are correctly connected, you will get a powerful electric heater that can provide heating of the coolant liquid for heating the building. Thanks to the generator, electric current with the required indicators is supplied to the inductor. This leads to the appearance of a magnetic vortex field on the turns of the coil.
The peculiarity of this field is the ability to change direction electromagnetic waves at high frequencies. If you place a metal object in it, it begins to heat up. Due to the lack of contact, when energy transfers from one type to another, losses will be minimal. Therefore, a self-assembled induction boiler has high efficiency.
To heat the coolant, it is enough to ensure its contact with a metal heater, for example, a tube. This is exactly how a flow heater works. Since water simultaneously cools the unit, its service life is significantly increased.
INDUCTION HEATER WITH YOUR OWN HANDS. HEATING THE METAL
Advantages and disadvantages
Having understood the operating principle of an induction heater, you can consider its positive and negative aspects. Considering the high popularity of heat generators of this type, it can be assumed that it has much more advantages than disadvantages. Among the most significant advantages are:
Since the performance indicator of an induction boiler is in a wide range, you can easily select the unit for specific system heating the building. These devices are capable of quickly heating the coolant to a given temperature, which made them a worthy competitor to traditional boilers.
During operation of the induction heater, a slight vibration is observed, due to which scale is shaken off the pipes. As a result, the unit can be cleaned less often. Since the coolant is in constant contact with the heating element, the risks of its failure are relatively small.
Part 1. DIY INDUCTION BOILER - it's easy. Device for induction hob.
If no mistakes were made during the installation of the induction boiler, then leaks are practically excluded. This is due to the contactless transfer of heat energy to the heater. Using induction water heating technology allows you to bring it almost to a gaseous state. In this way, efficient movement of water through the pipes is achieved, and in some situations it is even possible to do without the use of circulation pumping units.
Unfortunately, ideal devices do not exist today. Along with a large number of advantages, induction heaters also have a number of disadvantages. Since the unit requires electricity to operate, in regions with frequent power outages it will not be able to operate with maximum efficiency. When the coolant overheats, the pressure in the system increases sharply and the pipes can burst. To avoid this, the induction heater must be equipped with an emergency shutdown device.
Depending on your needs, you can independently make an induction heater of varying power. This can be not only a boiler for a heating system, but also a device designed to operate on a voltage of 12 V.
Simple heater
Such a device consists of two main elements - a generator and a coil with a low inductance. A simple electric heater will operate from a supply voltage of 12V. A self-exciting generator transmits pulses to an inductor, in which a magnetic field with a frequency of about 35 kHz appears. When placed at the center of the coil metal object, it will start to heat up. At home, this device can be used for non-contact welding, spot heating of material, and also hardening of metal parts.
It is quite easy to assemble such an inductor according to the circuit with your own hands, since all the necessary radio components are indicated there.
Instead of Schottky diodes, you can use others. The main requirements for these parts are an operating current of 1 A and sufficient speed. It’s not difficult to make an induction coil with your own hands - just make 10 turns with a tap from the center. The thicker the wire used, the better.
Powerful unit
In industrial units, iron pipes are used as a heater. However, at home it will be quite difficult to obtain sufficient power to heat such elements. However, this doesn’t make much sense. Since the inductor can heat up any metal, then homemade heater can be modified. The housing for the unit can be a thick-walled plastic pipe, the material of which can withstand strong heat.
Its length can be about 1 m, and inner diameter equal to 50-80 mm. To connect the unit to the heating circuit, adapters must be installed. These devices are mounted in the upper and lower parts of the housing. The lower part of the plastic pipe is covered with a grill, after which the internal cavity of the housing is filled with small particles of iron.
When choosing a material for making filler, you should pay attention to the magnetic resistance indicator. The higher it is, the more actively the material will heat up. The protective grill installed in the lower part of the housing is selected depending on the size of the filler particles. When the internal cavity of the housing is filled, it is necessary to close it on top with a grill.
The induction coil is wound directly onto the body of the heating element. Based practical experience, to create an effective unit, the number of turns must be at least 90. It should also be remembered that there should be no gap between the turns. If this requirement is ignored, noise may occur during operation. As for the winding material, then it is enough to use an insulated conductor with a cross section of 1 to 1.5 mm 2.
The heating element must be mounted so that its lower part is connected to the return line. The easiest way to use a generator is to use an inverter from an old welding machine. The main requirement here is the ability to adjust the current from a minimum level of 10 A. All that remains is to connect the coil to the inverter and apply supply voltage to it. Immediately after this, the unit will begin to work.
During development homemade device It is important to remember to use it safely. To avoid problems, you should purchase special means emergency shutdown. And industrial products are already equipped with serious means of protection.
The popularity of the IR2153 induction heater can be explained by the fact that a person is always in search - an endless search by a person for heat sources to heat his home, which will be: economical, environmentally friendly and functional. Many even dared, and for good reason, to make an induction heater with their own hands in order to connect it to the heating system of their home. The article will describe in detail how to make an inductor heater in order to spend a minimum Money and time.
Induction heater circuit
Due to the fact that M. Faraday discovered the phenomenon back in 1831 electromagnetic induction, the world saw a large number of devices that heat water and other media.
Because this discovery was realized, people use it in everyday life:
- Electric kettle with disk heater for heating water;
- Multicooker oven;
- Induction hob;
- Microwaves (stove);
- Heater;
- Heating column.
The opening is also used for an extruder (not mechanical). Previously, it was widely used in metallurgy and other industries related to metal processing. A factory-made induction boiler operates on the principle of the action of eddy currents on a special core located in the internal part of the coil. Foucault eddy currents are superficial, so it is better to take a hollow metal pipe as a core through which the coolant element passes.
The occurrence of electric currents occurs due to the supply of alternating electrical voltage to the winding, causing the appearance of an alternating electric magnetic field, which changes potentials 50 times/sec. at a standard industrial frequency of 50 Hz.
In this case, the Ruhmkorff induction coil is designed in such a way that it can be connected directly to an AC power supply. In production, high-frequency electric currents are used for such heating - up to 1 MHz, so it is quite difficult to achieve the operation of the device at 50 Hz. The thickness of the wire and the number of winding turns used by the device, water heater, are calculated separately for each unit according to special method for the required heat output. A homemade, powerful unit must function efficiently, quickly heat the water flowing through the pipe and not heat up.
Organizations invest serious funds in the development and implementation of such products, therefore:
- All problems are resolved successfully;
- The efficiency of the heating device is 98%;
- Functions without interruption.
In addition to the highest efficiency, one cannot help but be attracted by the speed at which the medium passing through the core is heated. In Fig. A diagram of the functioning of an induction water heater created at the plant is proposed. Such a scheme has a unit of the “VIN” brand, which is produced by the Izhevsk plant.
How long the unit will operate depends solely on how sealed the housing is and how the insulation of the wire turns is not damaged, and this is quite a significant period, according to the manufacturer - up to 30 years.
For all these advantages, which the device 100% has, you need to shell out a lot of money; an induction, magnetic water heater is the most expensive of all types of heating installations. Therefore, many craftsmen prefer to assemble an ultra-economical heating unit themselves.
Making an induction heater with your own hands
Making an invention is not difficult, if you have the skills, you can do it good device. The simplest unit, which is assembled by hand, consists of a piece of pipe (plastic), inside which various elements (metal) are arranged to create a core.
2.jpg)
It could be:
- Stainless steel wire;
- Wire rolled into balls, chopped into small pieces - wire rod, the diameter of which is 8 mm;
- Drill according to pipe diameter.
WITH outside fiberglass sticks are glued to it, and a 1.7 mm thick wire in insulation needs to be wound around them. The length of the wire is approximately 11 m. Then the induction heater must be tested by filling it with water and connecting it, for example, to an ORION induction hob with a power of 2 kW instead of a standard inductor. A vortex radiator welded from several metal pipes acts as an external core for eddy currents created by a coil of the same panel.
As a result, we can draw the following conclusion:
- The heat power of the manufactured heating device is higher than the electrical power of the panel.
- The number and size of the tubes were chosen randomly but provided sufficient surface area for the heat generated by the eddy currents.
- This water heater design turned out to be successful for a specific case when the apartment space is surrounded by other apartments that are heated.
The device works correctly, so if you have the desire, experience and knowledge, you can bring this idea to life. For complex models, it may be necessary to use a 3-phase transformer.
High precision induction heating
This heating has the simplest principle, since it is non-contact. High-frequency pulse heating makes it possible to achieve the highest temperature conditions, at which it is possible to process the most difficult metals to melt. To perform induction heating, you need to create electromagnetic fields the required voltage is 12V (volts) and the frequency of the inductance.
This can be done in a special device - an inductor. It is powered by electricity from an industrial power supply at 50 Hz.
It is possible to use individual power supplies for this – converters/generators. The simplest device for a low-frequency device is a spiral (insulated conductor), which can be placed in the inside of a metal pipe or wound around it. The flowing currents heat the tube, which subsequently supplies heat to the living space.
The use of induction heating at minimum frequencies is not common. The most common processing of metals is at higher or medium frequencies. Such devices are distinguished by the fact that the magnetic wave travels to the surface, where it attenuates. The energy is converted into heat. For the best effect, both components must have a similar shape. Where is heat applied?
Today, the use of high-frequency heating is widespread:
- For melting metals and soldering them using a non-contact method;
- Mechanical engineering industry;
- Jewelry;
- Creation small elements(boards) that may be damaged when using other methods;
- Hardening of surfaces of parts of various configurations;
- Heat treatment of parts;
- Medical practice (disinfection of devices/instruments).
Heating can solve many problems.
Advantages: induction heating of metal
Heating has many benefits. With its help, it is possible to quickly heat and melt any conductive material to a liquid state. Makes it possible to perform heating in any environment that does not conduct current, that is, the melting-working function.
Because only the conductor heats up, the walls remain cold. This type of heating does not pollute the environment. If gas burners pollute the air, then induction heating eliminates this, because of how electromagnetic radiation works. Compact dimensions of the inductor. Possibility of creating a device of any shape.
Heating is indispensable if you need to heat only a selected area on the surface. The device can also configure such special equipment to the required mode and adjust it.
How to make an induction heater from a computer power supply
The heater can be made from a computer power supply.
Will need:
- Throttle from the computer unit;
- Soldering iron;
- Welding machine;
- Wire cutters;
- Stainless steel wire 6 mm;
- Enameled flat copper wire 2mm;
- Steel pipes 25 mm;
- Plastic pipe 50 mm;
- Durable sanitary fittings;
- Explosion valve;
- Parts for assembling the circuit.
The boiler consists of a coil, a heat exchanger, a terminal box, a control cabinet, inlet and outlet pipes. The installation is simple, the main thing is to follow the diagram. Good laboratory block nutrition can be developed in a day and implemented in a day. Devices are connected through a transformer point.
Simple DIY inductor
A HDTV inductor can often come in handy in home life.
This device is often used to heat stuck:
- Nuts/bolts;
- Car frames and beams;
- Parts for car service, including bearings and various bushings.
Such devices can be bought in a specialized store, just like any other equipment, for example, an inverter Chinese air conditioner, a seismic sensor, but they are very expensive. However, there is a way out; it is quite possible to create an induction heater at home. For assembly you will need a transformer, it can be made from 2 rings. Ferrite grade can be used M 2000 NM.
The primary winding should contain approximately 26 turns of wire with a diameter of 0.75 mm. The primary winding is connected where the inverter comes out. The second winding consists of one loop of copper tube 6 mm in diameter, it is also the outlet of the inductor-tube, which passes through the center of the annular part of the transformer.
The inductor itself is a coil of several turns of a copper tube - 4 mm.
The capacitor, together with the device, performs the work of an oscillation circuit that creates a resonance frequency to which the inverter is tuned. If a workpiece is placed in the central part of the copper spiral, it will provide active resistance. High frequency frequencies arise in the coil itself, so the tube with the coils gets very hot, which means it needs to be mandatory cool, for this it is possible to use ordinary water from pipelines.
To connect to the inductor, it is necessary to use dielectric tubes, since a high voltage develops in the circuit. The running water that cools the inductor requires constant monitoring, so a special insert is installed in the drain, to which a thermocouple and a tester are attached to monitor temperature regime. The device should use a powerful capacitor; it can be assembled from forty high voltage capacitors by 0.033 µF each.
DIY induction heater (video)
As you can see, making an inductor with your own hands is not difficult, the main thing is to follow the diagram, you can also create an induction horn or assemble a circuit using thyristors or any other, for example, the internal contents of a transistor.
INDUCTION HEATER- it's electric heater, operating when changing the flux of magnetic induction in a closed conducting loop. This phenomenon is called electromagnetic induction. Want to know how an induction heater works? ZAVODRR- this is a trading informational portal, where you will find information about heaters.
Vortex induction heaters
An induction coil is capable of heating any metal, heaters are assembled using transistors and have a high efficiency of more than 95%; they have long replaced lamp induction heaters, whose efficiency did not exceed 60%.
A vortex induction heater for non-contact heating has no losses in adjusting the resonant coincidence of the operating parameters of the installation with the parameters of the output oscillatory circuit. Vortex-type heaters assembled on transistors are able to perfectly analyze and adjust the output frequency in automatic mode.
Metal induction heaters
Heaters for induction heating of metal have a non-contact method due to the action of a vortex field. Different types of heaters penetrate the metal to a certain depth from 0.1 to 10 cm, depending on the selected frequency:
- high frequency;
- average frequency;
- ultra high frequency.
Metal induction heaters allow you to process parts not only in open areas, but also to place heated objects in isolated chambers in which you can create any environment, as well as a vacuum.
Electric Induction Heater
High Frequency Electric Induction Heater Every day it acquires new ways of application. The heater operates on AC electric current. Most often, induction electric heaters are used to bring metals to required temperatures during the following operations: forging, soldering, welding, bending, hardening, etc. Electric induction heaters operate at high frequency 30-100 kHz and are used for heating various types media and coolants.
Electric heater used in many areas:
- metallurgical (HDTV heaters, induction furnaces);
- instrument making (soldering of elements);
- medical (production and disinfection of instruments);
- jewelry (jewelry manufacturing);
- housing and communal services (induction heating boilers);
- food (induction steam boilers).
Medium Frequency Induction Heaters
When deeper heating is required, medium-frequency type induction heaters are used, operating at medium frequencies from 1 to 20 kHz. Compact inductor for all types of heaters can be the most different shapes, which is selected so as to ensure uniform heating of samples of a wide variety of shapes, while it is also possible to carry out a given local heating. The mid-frequency type will process materials for forging and hardening, as well as through heating for stamping.
Easy to operate, with efficiency up to 100%, induction mid-frequency heaters are used for a wide range of technologies in metallurgy (also for smelting various metals), mechanical engineering, instrument making and other fields.
High Frequency Induction Heaters
The widest range of applications is for high-frequency induction heaters. The heaters are characterized by a high frequency of 30-100 kHz and a wide power range of 15-160 kW. The high-frequency type provides shallow heating, but this is enough to improve Chemical properties metal
High-frequency induction heaters are easy to operate and economical, and their efficiency can reach 95%. All types operate continuously for a long time, and the two-block version (when the high-frequency transformer is placed in a separate block) allows round-the-clock operation. The heater has 28 types of protection, each of which is responsible for its own function. Example: monitoring water pressure in a cooling system.
Ultra High Frequency Induction Heaters
Microwave induction heaters operate at superfrequencies (100-1.5 MHz) and penetrate to a heating depth (up to 1 mm). The ultra-high-frequency type is indispensable for processing thin, small, small-diameter parts. The use of such heaters allows one to avoid unwanted deformations associated with heating.
Ultra-high-frequency induction heaters based on JGBT modules and MOSFET transistors have power limits of 3.5-500 kW. They are used in electronics, in the production of high-precision instruments, watches, jewelry, for the production of wire and for other purposes requiring special precision and filigree.
Forge induction heaters
The main purpose of forging-type induction heaters (IH) is heating of parts or parts thereof, prior to subsequent forging. The blanks can be the most different types, alloy and shape. Induction forging heaters allow you to process cylindrical workpieces of any diameter in automatic mode:
- economical, as they only take a few seconds to heat up and have a high efficiency of up to 95%;
- easy to use, allow for: full process control, semi-automatic loading and unloading. There are options with full automation;
- are reliable and can work continuously for a long time.
Induction shaft heaters
Induction heaters for hardening shafts work together with the hardening complex. The workpiece is in a vertical position and rotates inside a stationary inductor. The heater allows the use of all types of shafts for consistent local heating; the hardening depth can be fractions of millimeters in depth.
As a result of induction heating of the shaft along its entire length with instant cooling, its strength and durability increases many times over.
Induction pipe heaters
All types of pipes can be treated with induction heaters. The heater for pipes can be air- or water-cooled, with a power of 10-250 kW, with the following parameters:
- Air Cooled Tube Induction Heating produced using a flexible inductor and a thermal blanket. Heating temperature up to temperature 400 °C, and use pipes with a diameter of 20 - 1250 mm with any wall thickness.
- Induction heating water cooled pipe has a heating temperature of 1600 °C and is used for “bending” pipes with a diameter of 20 - 1250 mm.
Each heat treatment option is used to improve the quality of any steel pipe.
Pyrometer for heating control
One of the most important parameters operation of induction heaters - temperature. For more careful monitoring of it, in addition to built-in sensors, infrared pyrometers are often used. These optical devices allow you to quickly and easily determine the temperature of hard-to-reach (due to high heat, the possibility of exposure to electricity, etc.) surfaces.
If you connect a pyrometer to an induction heater, you can not only monitor the temperature, but also automatically maintain the heating temperature for a specified time.
Operating principle of induction heaters
During operation, a magnetic field is formed in the inductor, into which the part is placed. Depending on the task (depth of heating) and the part (composition), the frequency is selected; it can be from 0.5 to 700 kHz.
The principle of operation of the heater according to the laws of physics states: when a conductor is in an alternating electromagnetic field, an EMF (electromotive force) is formed in it. The amplitude graph shows that it moves proportionally to the change in the speed of the magnetic flux. Due to this, eddy currents are formed in the circuit, the magnitude of which depends on the resistance (material) of the conductor. According to the Joule-Lenz law, current leads to heating of a conductor that has resistance.
The operating principle of all types of induction heaters is similar to a transformer. The conductive workpiece, which is located in the inductor, is similar to a transformer (without a magnetic core). The primary winding is an inductor, the secondary inductance of the part, and the load is the metal resistance. During high-frequency heating, a “skin effect” is formed; eddy currents that form inside the workpiece displace the main current onto the surface of the conductor, because the heating of the metal on the surface is stronger than inside.
Advantages of induction heaters
An induction heater has undoubted advantages and is a leader among all types of devices. This advantage is as follows:
- It consumes less electricity and does not pollute the surrounding space.
- Easy to use, it provides high quality work and allows you to control the process.
- Heating through the walls of the chamber ensures special purity and the ability to obtain ultra-pure alloys, while melting can be carried out in different atmospheres, including inert gases and vacuum.
- With its help, it is possible to uniformly heat parts of any shape or selective heating
- Finally, induction heaters are universal, which allows them to be used everywhere, displacing outdated energy-consuming and inefficient installations.
Repair of induction heaters is carried out using spare parts from our warehouse. At the moment we can repair all types of heaters. Induction heaters are quite reliable if you strictly follow the operating instructions and do not allow excessive operating conditions - first of all, monitor the temperature and proper water cooling.
The subtleties of operation of all types of induction heaters are often not fully published in the manufacturers' documentation; their repairs should be carried out by qualified specialists who are well acquainted with the detailed operating principle of such equipment.
Video of induction mid-frequency heaters working
You can watch the video of the operation of a mid-frequency induction heater. The mid-frequency is used for deep penetration in all types metal products. The medium frequency heater is a reliable and modern equipment, which works all day long for the benefit of your enterprise.