Induction Heating - Superior Heating Strategies for Industrial Processes
The Modular Heating System (MHS) consists of a controller and up to seven generator modules that provide optimally adapted power for inductors.
Induction heating systems are designed for manufacturing processes that involve electrical heat. This includes drying processes in the plastics processing and textile industries as well as in the paper industry.
Induction heaters are increasingly used to heat tools, such as rolls, rollers or cylinders. They are not only emission-free, but also provide heat quickly and turn it off again just as quickly. The induction heat (up to 250°) can be distributed evenly and allows dynamic control as required.
The technology is based on the eddy current principle, where an alternating magnetic field is generated with the help of a high-frequency alternating current, which is introduced into the metal in a specific way. The resulting eddy current losses generate heat energy, which can be precisely measured by varying the current. Due to the precise controllability of the temperature, the heating process can be reproduced precisely, thus ensuring a high quality of the process. The temperature is measured directly in the jacket with up to four measuring points. In addition, a multi-zone design enables uniform heating of the surface and roller inductors.
Industrial induction heating systems are equipped with various features to meet the specific requirements of different applications. Here are some common features found in industrial induction heating systems:
Power Control: These systems offer precise control over power output, allowing users to adjust the heating intensity according to their needs. Power control can be achieved through manual adjustment or programmable settings.
Frequency Control: Induction heating systems often provide the flexibility to adjust the frequency of the alternating current. Different frequencies are suitable for heating various materials and achieving different heating depths.
Temperature Monitoring: Industrial systems incorporate temperature monitoring capabilities to ensure accurate and consistent heating. Temperature sensors, such as thermocouples or infrared cameras, are used to measure and monitor the temperature of the workpiece during the heating process.
Heating Profile Control: Advanced systems enable users to define and control the heating profile, including ramp-up rates, dwell times, and cooling rates. This feature is particularly useful for achieving specific heat treatment results or meeting precise heating specifications.
Automatic Heating Cycles: Many industrial induction heating systems offer the ability to program and automate heating cycles. Users can define multiple heating steps, time durations, and power levels, allowing for efficient and repeatable heating processes.
Cooling System Integration: To facilitate the quenching process, some induction heating systems incorporate integrated cooling systems. These systems can provide a controlled and efficient means of quenching the workpiece after heating, ensuring consistent and effective hardening results.
Safety Features: Industrial systems prioritize safety and incorporate various features to protect operators and equipment. These may include emergency stop buttons, overheat protection mechanisms, fault diagnostics, and electrical and thermal safety interlocks.
User Interface: The user interface of an industrial induction heating system is designed to be user-friendly and intuitive. It may include a touchscreen display, control knobs, and buttons for easy operation and configuration of heating parameters.
Data Logging and Connectivity: Advanced systems offer data logging capabilities to record and store key process parameters such as temperature, power, and time. They may also provide connectivity options, such as USB or Ethernet, to transfer data to external devices or integrate with other control systems.
Modular Design: Some systems feature a modular design, allowing for flexibility and scalability. Additional heating stations or coils can be added to the system, providing versatility for different workpiece sizes or multiple simultaneous heating processes.
What is induction heating in industrial processes?
Induction heating is a fast and non-contact method of heating metals, especially ferrous metals.
What is induction heating?
Induction heating systems are used in machines that require process heating, such as heated rolls or tools. They are used in food processing, the textile industry or the printing and paper industry.
How does induction heating work?
A high-frequency alternating current is applied to an induction coil, which creates an electric field. The workpiece to be heated is placed in this area. The resulting eddy currents generate heat directly in the workpiece.
What does an induction heating system consist of?
Industrial induction heating systems typically consist of an induction generator and an inductor. With modular heating systems, it is possible to build systems with up to seven generators and 42 inductors.
What are the advantages of induction heating?
The temperature, heating time and heating pattern are reproducible. With induction heating systems, you can convert 90% of the consumed energy into usable heat without burning fossil fuels. Due to the high surface power and low mass, typical workpieces can reach process temperature in a very short time. By designing the inductor and using multiple heating zones, very precise surface temperatures can be achieved, while the entire heating process can be controlled by the induction generator and process control software.
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