Induction

10 Steps To Troubleshoot Your Induction System

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OC

Nikola Tesla said, “If you want to find the secrets of the universe, think in terms of energy, frequency, and vibration.” These three components are evident in getting to know the inner workings of an induction system. When it comes to troubleshooting such a system at in-house heat treat departments, this 10 step guide will help heat treat operators understand the secrets of induction and solve common problems that may arise.

This original content article was first written by Alberto Ramirez, engineer of Power Supply and Automation at Contour Hardening, Inc. and an honoree from Heat Treat Today’s 40 Under 40 Class of 2021, for Heat Treat Today's May 2023 Sustainable Heat Treat Technologies print edition.

Alberto Ramirez
Power Supply and Automation Engineer
Contour Hardening, Inc.

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Metals can be heated by the process of electromagnetic induction, whereby an alternative magnetic field near the surface of a metallic (or electrically conductive) workpiece induces eddy current (and thus heat) within the workpiece. Induction systems can be complex systems that aim to heat treat specific parts or sections of a mechanical component; depending on the degree of complexity of the part to be treated, it will be the challenge of a professional to detect any problem.

1. Familiarize Yourself with the Process

Figure 1. Induction hardening process
Source: Contour Hardening, Inc.

The induction process involves many characteristics such as: position of the piece within the induction coil, load positions, cooling positions, cycle times, applied electric power, and others. It is important that the professional can identify the failure and the particular situation at the moment in which it is occurring.

On some occasions, the failures are not evident and therefore it is essential to analyze the part that has been treated. This analysis can be key to understanding situations such as poor depth due to electrical power or decrease in output frequency, among other possible scenarios.

In addition to the analysis of the piece, it is vital to inspect the “crime scene,” since many of the induction systems — given the nature of the process and the danger involved in handling high electrical potentials — are usually highly automated and the work stations are difficult for staff to access. A good work strategy consists of carefully observing the general conditions of the equipment to determine where the problem will begin to be solved.

2. Identify Main Components and Certain Security Mechanisms of Your Induction System

Understanding the interrelationship of the system is important to comprehend which element performs a certain action, as well as the communication channels between them. Once this knowledge is generated, a failure can be associated with a particular component. Induction systems are usually made up of the elements in Figure 2.

Figure 2. Induction system components
Source: Contour Hardening, Inc.

As we mentioned before, the process involves high electrical potentials, and for this reason, the nature of the power supplies involves power electronic devices such as electrical capacitors, which store energy. Therefore, it is important to electrically discharge the system before beginning to inspect a piece of equipment.

3. Have the Necessary Tools Ready To Carry Out a Good Analysis of the Problem

Figure 3. Capacitors
Source: Contour Hardening, Inc.

Like any technical problem, the use of a mechanical tool is essential when carrying out some type of project, but for the diagnosis of failure in induction equipment it is important to have:

  • Oscilloscope
  • Function generator
  • Ammeter
  • Digital and analog multimeter
  • High voltage probes

Without these elements it is exceedingly difficult to reach a reliable diagnosis, and the possibility of finding the fault is minimal. Therefore, having these meters in good condition and above all, calibrated, gives a clearer perspective of the problem.

4. Verify that the Process Sensors, Power Monitors, and Induction Coils Are Working Properly

There are different meters that collect information about the process. This information can mostly be viewed through the HMI (human machine interface). On many occasions, a good way to begin to understand the problem is by collecting the information on the process. If these meters do not work correctly, they can lead you to wrong conclusions.

Verify the energy meters are working correctly, as well as your input and output signals.

Induction coils are a key element in the induction process since, according to their geometry, they generate the appropriate magnetic fields to achieve the expected metallurgical results. If there are water leaks or the electrical transmission elements are loose or dirty, it could be the root cause of the problem. It is important to start troubleshooting once this circuit is ruled out.

Figure 4. Energy parameters example
Source: Contour Hardening, Inc.

5. Carry Out Studies of Constant Energy in Your Substation To Identify Possible Problems in Your Energy Supply, Including Critical Times

Electrical energy is the main source in an induction process, power supplies transform and potentiate this resource to create electronic fields strong enough to generate heat in the piece.

Therefore, it is important to find evidence that rules out failures of the electrical system that the induction system is a part of. In the same way, understanding how our electrical system behaves can help us generate behavior patterns that can determine the solution at specific times when it may arise.

6. Document Your Work Methodically and Take One Step at a Time

Induction systems can be very intimidating if you have not had previous experience, and, like any element or situation, it is important to logically approach the problem by analyzing the failure mode, identifying the main parts that interact at that specific moment. From there, document and take small steps, one at a time. If you don’t, it is very likely you will lose all the work you have done, and the situation will get worse.

Figure 5. Before and after of an arc at the transmission line
Source: Contour Hardening, Inc.

If the moves are unsuccessful, you can always return to your starting point and try another approach. The idea is that the failure mode remains the same no matter what moves you make until the problem is resolved. In this way you will have the failure contained, otherwise you could be damaging other elements without realizing it.

It is very important to understand that the processes are sequences that precede and proceed new events. If you understand the process and solve a problem, but now have a new failure, it is important to analyze if this failure is the continuation of the process. If so, it is possible that you find yourself in a case where an event is triggering a series of failures. Therefore, a more in-depth analysis must be carried out. The idea to generate is to get to the root cause and mitigate the risk.

7. Try Any Possibility Related to the Process Regardless of Whether the Relationship Between It and the Problem Is Not Direct

Logical thinking can solve most of the technical failures of a system. For exceptional failures, however, it is necessary to use your imagination and exhaust all possible resources, since the smallest area of interest or the least thoughtful place can be the key to solving a problem.

8. Get To Know Your Power Supplies

One of the key factors in any induction equipment is its power supplies. Power supplies are equipment that do not require such arduous maintenance compared to other systems in the industry, but if the minimum maintenance conditions are not present, they can generate high losses for the organization.

Figure 6. Flow diagram of the energy process at the power supply
Source: Contour Hardening, Inc.

In cases where the problem is the power supplies, it is vital that the same methodical process previously described is followed. Understanding how the energy transformation process works will give you an advantage, as will knowing the elements that compose them or the type of technology used in the rectification process, in the inversion (solid state or electron tubes) and in the resonant circuit. Generally, power supplies follow the transformation in Figure 6.

9. Identify the Critical Parts of Your Induction Equipment and Prepare an Inventory

Figure 7. Coil damage
Contour Hardening, Inc.

Usually, the elements that belong to the power supplies are difficult to obtain depending on the age of your equipment. With the recent microchip crisis in the market, control and automation elements have very long delivery times or the prices are very high. Therefore, it is vital that there is a list of critical parts and an inventory of these.

In addition to the elements described, induction coils are usually very characteristic and important elements in the induction process. These coils are complex elements that have been designed exclusively for the piece, so their manufacture can take several weeks, and the necessary precautions must be taken to maintain a constant maintenance movement.

10. Perform Preventative Measurements to the System To Generate a Pattern of Behavior

Figure 8. Possible examples of measurements
Contour Hardening, Inc.

When the system is working in optimal conditions, generate a measurement plan which allows you to generate information on specific points within the system. Once a new failure occurs again you can compare the measurements of failure against those of good performance. Some examples of measurements can be:

  • Temperature
  • Voltage
  • Current
  • Resistance and capacitance
  • Waveforms

Summary

An orderly and documented work methodology, a good spare parts catalog, and the necessary work tools can be key elements to understand a problem and, more importantly, to solve it effectively.

It is vital that professionals are in continuous training in order to decrease downtime due to failures in induction systems. Training related to metallurgical processes would be a good way to complement your resolution skills by being able to interpret the characteristics of induction systems with the elements that compose it.

 

References

Valery Rudnev and George Totten, ed., ASM Handbook Volume 4C: Induction Heating and Heat Treatment, (Materials Park, OH: ASM International Heat Treating Society, 2014), 581- 583.

 

About the Author: Alberto C. Ramirez graduated from the National Technical Institute of Mexico as a mechatronics engineer. He earned his master’s degree in information technology administration from Monterrey Institute of Technology. With more than eight years of experience in power supplies, project management, maintenance, and automation, he currently works as a Power Supply and Automation Engineer at Contour Indianapolis. Alberto began his career at the Contour subsidiary in Mexico and due to his dedication, he is part of the staff in the United States. He is also an honoree from Heat Treat Today's 40 Under 40 Class of 2021.

For more information:

Contact Alberto at Contact Alberto at aramirez@contourhardening.com.

 

 

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Induction Through Heating + Intensive Quenching: A “Green Ticket” for Steel Parts

/ CARBURIZING TECHNICAL CONTENT, FEATURED NEWS, INDUCTION HEATING EQUIPMENT TECHNICAL CONTENT, INDUCTION HEATING TECHNICAL CONTENT, MANUFACTURING HEAT TREAT, QUENCHING TECHNICAL CONTENT

OCOn site at heat treat operations, gas-fired furnaces can be a significant source of carbon emissions. But depending on the desired heat treatment, an alternative approach that combines induction through heating and intensive quenching could be the “green ticket.” Learn about the ITH + IQ technique and discover how certain steels may benefit from this approach.

This Technical Tuesday article was composed by Edward Rylicki, Vice President Technology, and Chris Pedder, Technical Manager Heat Treat Products and Services, at Ajax TOCCO Magnethermic Corp., and Michael Aronov, CEO, IQ Technologies, Inc. It appears in Heat Treat Today's May 2023 Sustainable Heat Treat Technologies print edition.

Introduction

Chris Pedder,
Technical Manager Heat Treat Products and Services, Ajax TOCCO Magnethermic Corp.
Source: Ajax TOCCO Magnethermic Corp.

Induction heating is a green, environmentally friendly technology providing energy savings and much greater heating rates compared to other furnace heating methods. Other advantages of induction heating include improved automation and control, reduced floor space, and cleaner working conditions. Induction heating is widely used in the forging industry for heating billets prior to plastic deformation. Induction heating is also used for different heat treatment operations such as surface and through hardening, tempering, stress relieving, normalizing, and annealing. However, the amount of steel products subjected to induction heating in the heat treating industry is much less compared to that processed in gas-fired furnaces.

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Gas-fired heat treating equipment is a major source of carbon emissions in the industry. As shown in Reference 1, induction through heating (ITH) followed by intensive quenching (IQ) (an “ITH + IQ” technique) eliminates, in many cases, the need for a gas-fired furnace when conducting through hardening and carburizing processes — the two most widely used heat treating operations for certain steel parts. Eliminating gas-fired furnaces will result in significant reduction of carbon emissions at on-site heat treat operations.

Dr. Michael Aronov,
CEO, IQ Technologies, Inc.
Source: Ajax TOCCO Magnethermic Corp.

The goal of this article is twofold: 1) to evaluate carbon emissions generated during through hardening of steel parts and carburizing processes when conducted in gas-fired furnaces, and 2) to discuss how these emissions can be reduced to zero using the ITH + IQ process.

Evaluation of Carbon Emissions for Through Hardening and Carburizing Processes

Ed Rylicki,
Vice President Technology, Ajax TOCCO Detroit Development & Support Center
Source: Ajax TOCCO Magnethermic Corp.

Most through hardening and carburizing operations for steel parts are conducted in batch and continuous integral quench gas-fired furnaces. Assumptions made for evaluating CO2 emissions produced by a typical integral quench furnace are presented in Table 1. Note: The values of carbon emissions presented Table 1 are conservative since they don’t consider the amount of CO2 produced by furnace flame screens and endothermic gas generators used to provide a controlled carburizing atmosphere in the furnace. Also, it’s assumed that the furnace walls are already heated through when loading the parts, so there are no heat losses associated with the thermal energy accumulated by the furnace walls.

Table 1. Assumptions for calculating of carbon emissions by integral quench furnace
Source: Ajax TOCCO Magnethermic Corp.

Emissions Generated During the Through Hardening Process

A furnace time/temperature diagram for the through hardening process considered is presented in Figure 1. Carbon emissions Ehard produced by the furnace considered during heating of the load to the austenitizing temperature prior to quenching are calculated by using the following equation,

 

(Equation 1)
Ehard = k • Qhard

where:

■ k = the emission coefficient (equal to 0.050 • 10-3 kg per 1 kJ of released energy when burning natural gas (see Reference 2)
■ Qhard = thermal energy required for heating up the above load from ambient to the austenitizing temperature

A value of Qhard is calculated by the equation below,

(Equation 2)

Qhard = M • C • (Ta -To) / Eff = 1,135 • 0.56 • (843 - 20) / 0.65 = 0.805 • 106kJ

where:

■ M = load weight, kg
■ C = steel specific heat capacity (kJ/kg°C)
■ Ta = part austenitizing temperature (°C)
■ To = part initial temperature (°C)
■ Eff = furnace thermal efficiency (a ratio of the furnace thermal losses to the gross heat input)

From equations (1) and (2), the amount of carbon emissions produced by the above furnace during one hardening operation is 40.2 kg. To determine an annual amount of carbon emissions, calculate the number of hardening cycles per year (Nhard) run in the furnace. From Figure 1, a duration of one hardening cycle is 4 hours (3 hours for austenitizing of the parts plus 1 hour for quenching the parts in oil and unloading/loading the furnace). Thus, Nhard is equal to:

Nhard = 360 day • 24 hour • 0.85 / 4 hour = 1826

Figure 1
Source: Ajax TOCCO Magnethermic Corp.

Annual CO2 emissions from one integral quench batch gas-fired furnace are 40.2 • 1836 = 73,807 kg, or more than 73 t

Emissions Generated During Carburizing Process

A simplified furnace time/temperature diagram for the carburizing process considered is presented in Figure 2. Carbon emissions (Ecarb) produced by the above furnace during the carburizing process are calculated by the following equation,

(Equation 3)

Ecarb = k • Qcarb

where:

■ Qcarb = a thermal energy expended by the furnace during the carburizing process. A value of Qcarb amounts to two components: 

(Equation 4)

Qcarb = Qcarb1 + Qcarb2

Qcarb in the following equation is:

■ Qcarb1 = energy required for heating up the load to the carburizing temperature
■ Qcarb2 = energy needed for maintaining the furnace temperature during the remaining duration of the carburization process (for compensation of the furnace thermal losses since the parts are already heated up to the carburizing temperature)

A value of Qcarb1 is calculated using equation (2) where the part carburizing temperature Tc is used instead of part austenitizing temperature Ta (see Table 1):

Qcarb1 = 1,135 • 0.56 • (927 – 20) / 0.65 = 0.887 • 106 kJ

A value of Qcarb2 is a sum of the flue gas losses and losses of the thermal energy through the furnace walls by heat conduction. Qcarb2 is evaluated from the following considerations. Since the assumed furnace thermal efficiency is 65%, the furnace heat losses are equal to 35% of the gross heat input to the furnace. Hence, the furnace heat losses Qloss1 during the load heat up period (the first 3 hours of the carburizing cycle, see Figure 2) are the following:

Qloss1 = Qcarb1 • 0.35 = 0.887 • 106 • 0.35 = 0.31 • 106 kJ.

The furnace heat losses during the remaining 8 hours of the carburizing cycle Qloss2 are proportionally greater and are equal to:

Qloss2 = Qloss1 • 8 hr /3 hr = 031 • 106 • 8 /3 = 0.827 • 106 kJ

Thus, the total amount of the thermal energy expended by the furnace during the carburizing cycle is Qcarb = 0.887 • 106 + 0.827 • 106 = 1.71 • 106 kJ. The total amount of the CO2 emissions from carburizing of the load in the furnace considered according to equation (3) is: Ecarb = 0.050 • 10-3 • 1.71 • 106 = 85.7 kg. To determine an annual amount of carbon emissions from one carburizing furnace, calculate the number of carburizing cycles run in the furnace per year. Per Figure 2, a duration of one carburizing cycle is 12 hour (1 hour for the furnace recovery plus 10 hour for carburizing of parts at 927°C plus 1 hour for quenching parts in oil and for unloading and loading the furnace). Thus, the number of carburizing cycles per year Ncarb is:

Ncarb = 360 day • 24 hr • 0.85 / 12 hr = 612

Figure 2
Source: Ajax TOCCO Magnethermic Corp.

Annual CO2 emissions from one integral quench batch carburizing furnace is about 85.7 • 612 = 52,448 kg, or more than 52 t.

Reducing Carbon Emissions Using the ITH + IQ Process

Reference 1 presents results of two case studies of the ITH + IQ process on automotive input shafts and drive pinions. The study was conducted with a major U.S. automotive part supplier. A two-step heat treating process was used for the input shafts, consisting of batch quenching parts in oil or polymer using an integral quench gas-fired furnace for core hardening followed by induction hardening. This two-step method of heat treatment is widely used in the industry for many steel products. It provides parts with a hard case and tough, ductile core.

Substituting the “ITH + IQ” method for the two-step heat treating process not only eliminates the batch hardening process, but also requires less alloy steel for the shafts that don’t require annealing after forging. Thus, in this case, applying the ITH + IQ technique eliminates two furnace heating processes for the input shafts, resulting in the reduction of the CO2 emissions to zero for the shafts’ heat treatment. Per client evaluation, as mentioned in Reference 1, the hardness profile in the intensively quenched input shafts was similar to that of the standard shafts. Residual surface compressive stresses in the intensively quenched shafts were greater in most cases compared to that of the standard input shafts, resulting in a longer part fatigue life of up to 300%.

Per Reference 1, the environmentally unfriendly  carburizing process can be fully eliminated in most cases for automotive pinions when applying the ITH + IQ method and using limited hardenability (LH) steels that have a very low amount of alloy elements. A case study conducted for drive pinions with one of the major U.S. automotive parts suppliers demonstrates the intensively quenched drive pinions met all client’s metallurgical specifications and passed both the ultimate strength test and the fatigue test. It was shown that the part’s fatigue resistance improved by about 150% compared to that of standard carburized and quenched in oil drive pinions. In addition, distortion of the intensively quenched drive pinions is so low that no part straitening operations were required.

Conclusion

Coupling Ajax TOCCO’s induction through heating method with the intensive quenching process creates a significant reduction of CO2 emissions produced during heat treatment operations for steel parts. For the through hardening process, eliminating just one batch integral quench gas-fi red furnace will reduce carbon emissions by more than 73 ton per year. For the carburizing process, eliminating just one batch carburizing furnace will reduce carbon emissions by more than 52 ton per year. Note that for continuous gas-fired furnaces, the carbon emission reduction will be much greater due to higher continuous furnaces production rates (hence a much higher fuel consumption).

Per our experience, the ITH + IQ process can be applied to at least 20% of the currently through-hardened and carburized steel parts. Per two major heat treating furnace manufacturers in the U.S., there are thousands of atmosphere integral quench batch and continuous furnaces in operation in the U.S. That means hundreds of gas-fired heat treating furnaces can be potentially eliminated, drastically reducing carbon emissions in the U.S., supporting a lean and green economy.

 

References

[1] Michael Aronov, Edward Rylicki, and Chris Pedder, “Two Cost-Effective Applications of Intensive Quenching Process for Steel Parts,”Heat Treat Today, October 2021, https://www.heattreattoday.com/processes/quenching/quenching-technical-content/two-cost-effective-applications-for-intensive-quenching-of-steel-parts/.

[2] U.S. Energy Information Administration.

About the Authors:

Ed Rylicki has been in the induction heating industry for over 50 years. He is currently Vice President Technology at Ajax TOCCO Detroit Development & Support Center in Madison Heights, Michigan.

Mr. Chris Pedder has over 34 years of experience at Ajax Tocco Magnethermic involving the development of induction processes in the heat treating industry from tooling concept and process development to production implementation.

Dr. Michael Aronov has over 50 years’ experience in design and development of heating and cooling equipment and processes for heat treating applications. He is CEO of IQ Technologies, Inc. and a consultant to the parent company Ajax TOCCO Magnethermic.

For more information: Contact info@ajaxtocco.com or 800.547.1527

 

 

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Upfront Planning: What To Expect with Induction Design and Fabrication

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OC

Induction heat treating: no harsh chemicals, gases, or even CO2 emissions. But to get there, heat treaters should first understand how to plan for an induction design and fabrication project upfront. Consider these five important factors before you dive into induction.

This Technical Tuesday article was composed by John Chesna, general manager at Induction Tooling, Inc. and honoree in Heat Treat Today's 40 Under 40Class of 2022. It appears in Heat Treat Today's May 2023 Sustainable Heat Treat Technologies print edition.

Introduction

John Chesna
General Manager at Induction Tooling
Source: Induction Tooling, Inc.

There are many less than obvious factors to consider when preparing and planning for induction. So where to start? There are five important factors that manufacturers with in-house heat treat operations should understand in order to successfully prepare an induction heating project and design.

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But first, what is induction heating? Induction heat treating is the process in which a high frequency conductor (induction tool) induces currents (eddy currents) into an electrically conductive workpiece. Without ever touching the work-piece, the current generated and the resistance causes heating. Ever since its proven usefulness around the time of World War II, induction has been chosen as the go-to heat treatment for a variety of applications across many industries including agricultural, medical, and transportation. Now, it seems that most industries have taken advantage of induction heat treating, and its popularity will likely only continue to increase with the push for the use of “clean” and “green” energy.

#1 Plan for Inductor Wear

One of the most important factors to an induction project is realizing the inductor/ coil is a wear item. It can be highly engineered, hand fabricated, machined, or even 3D printed. Yet, in the overall process, it is still a wear item: an item that will eventually require replacement or repair. The inductor is exposed to the worst of the elements during the induction process and can fail from standard use, accidents, or unforeseen circumstances. Inductor designers are constantly being challenged to create tools that will last longer, require less maintenance, or run more cycles. All of those can be achieved, but the inductor will eventually require replacing and that is not a bad thing!

A properly serviced and maintained inductor will ensure quality parts are being produced. As the inductor wears, the efficacy degrades, leading to undesirable results. Repair of the inductor will correct this issue and ensure the parameters required for the desired heat treat pattern are restored. Depending on production needs, a good principle is to have more than one inductor on hand so that while one is being repaired the spare inductor can remain on the machine to keep up with manufacturing demand. Planning for this is important for the project’s timing and budget.

#2 Types of Inductor Designs

Determining a specific inductor design will be necessary to properly heat parts. The inductor creates the magnetic field in the workpiece, and typically the inductor is shaped to couple closely where heat treatment of the part is desired. Additionally, if quenching is required for the heating application, this function will be considered in the inductor’s design. The inductor’s design must deliver the electrical energy and quench medium to the workpiece while allowing accessibility for material handling purposes. For this reason, inductors take on many different designs.

Common inductor designs include:

  • Pancake: used for heating flat surfaces
  • Single turn or multi-turn: commonly shown as copper tubing wrapped around cylindrically around the workpiece
  • Hairpin: typically, a simple back and forth loop used to heat long lengths internally or externally on the workpiece
  • Split return: used to focus the energy in particular areas of the workpiece
  • MIQ (machined integral quench) paddle: the most commonly used design for scanning applications

#3 Power and Frequency

Know the power supply and/or work-head power and frequency. Depending on the composition of the part that requires processing, the power and frequency of the equipment will help estimate the depth of the pattern that can be achieved, as well as help determine how successful the part will be for induction heating. Irregularly shaped geometries with points, holes, or sharp edges sometimes cause difficulty establishing eddy currents where the induction pattern is desired. Some parts, after review, are good candidates for induction heat treatment but cannot be processed with the existing power supply and/or work-head setup.

If an inductor is being built to mount to existing induction equipment, it is important to know the scope of parts that are currently being processed or expected to be processed on the machine. The electrical circuit of the power supply, work-head, and inductor must load match to the part. If a variety of parts are being run then multiple styles of inductors may exist or will be required to be used. Different designs of inductors, e.g., single-turn, multi-turn, or split return used on the machine will change the transformer effect and capacitor requirements of the system. Availability to tune the system capacitance and inductance becomes vitally important for operation. Please note that adjusting capacitance can be dangerous and should only be done by a trained technician. Newer power supplies function differently than older models, yet load tuning needs to be considered.

#4 Part Details

A detailed pre-induction print is needed. The print should list the material as well as the desired heat treatment pattern to determine the inductor design. As the print specifies the pattern, it should also provide limits. Inductors are then typically designed to the shape of the part. The inductor may require an integrated quench, electrically insulating protective coating, locators, or additional assembly fixturing depending on the part’s size. An inductor built for one part may be used or tried on a similar part. However, the same results cannot be expected to render on the part for which it was not designed. If the manufacturer knows that a family of parts will be run, the full scope should be presented to inductor designers for consideration before the build.

#5 Material Handler

Ideally an inductor supplier would be contacted to develop the induction heating process for a part; then, that information should be shared with the material handling designer. That would be the ideal, but that’s not the way it usually happens. Sometimes, a machine is built to process a part that no longer is in use, so the machine is now being retrofitted to process different parts. The design of a new inductor is needed to accommodate this existing machine which may create size constraints to the inductor’s design.

The contact style, how the inductor mounts to the work-head, will need to be determined. There are a variety of commonly used power supplies and work-heads available from OEMs in the market. As each OEM keeps their contacts standard to their equipment, there is no singular standard footprint in the market. Once the contact style has been determined, the inductor can be designed for maximum power delivery efficiency. How the part and inductor are presented to each other is important. The centerline distance, a measurement from where the inductor mounts to where the part will be processed, needs to be known. The centerline determines the required length of the inductor and indirectly how much room is available for the inductor’s design.

Conclusion

Due to the variety of factors, no two projects are ever the same. Induction heating is an exciting technology, and I encourage everyone to learn more about it.

 

About the Author: John Chesna is the general manager of Induction Tooling, Inc. and has been involved with the induction heat treating industry for over 8 years. He is a graduate of the University of Akron with a Bachelor of Science in Mechanical Engineering Technology. His responsibilities include overseeing day-to-day operations including the design, manufacturing, and testing of induction heat treating inductors. Additionally, John was a recipient of Heat Treat Today's 40 Under 40 award in 2022.

Contact John at jchesna@inductiontooling.com.

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8 Heat Treaters Improve Processes with Simulation Software

/ FEATURED NEWS, INDUCTION HEATING EQUIPMENT TECHNICAL CONTENT, INDUCTION HEATING TECHNICAL CONTENT, MANUFACTURING HEAT TREAT

Source: CENOS

Heat Treat Today brings you this best of the web content to highlight how 8 companies have been using simulation in their heat treat processes. In the article, the companies attest to saved time and costs as well as the benefits of visualizing accurate results. Check it out!

An excerpt:

[blockquote author=”CENOS” style=”1″]Old coil design failed and started leaking after 20,000 shots, while the redesigned coil is still running after 122,000 shots – more than five-fold improvement of the coil lifetime. By summing all of the benefits of the simulation software adoption in the engineering routine of the plant, Kevin got a 9% increase of the overall equipment efficiency (OEE).[/blockquote]

Read More: “8 Stories on How Computer Simulation Helped Companies to Improve Induction Heating in 2020”

 

 

All images provided by CENOS.

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3 Charter Members Join IHEA’s New Induction Heat Treating Division

/ FEATURED NEWS, HEAT TREAT NEWS, HEAT TREAT NEWS INDUSTRIES, INDUCTION HEATING NEWS

Ajax TOCCO Magnathermic, Ambrell and SMS Elotherm have all joined the Industrial Heating Equipment Association’s (IHEA) newest membership division — the Induction Division which focuses on keeping the industry up-to-date on the latest heat treat innovations, best practices and safety standards associated with induction heating. Several national utilities are also involved: Duke Energy, Georgia Power, Alabama Power, and the Electric Power Research Institute (EPRI). At least one other induction company is scheduled to join later this year.

The new division members are in the process of developing content for a 2016 Induction Seminar which will take place later this fall.

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