Induction Heating Systems for Metal Industries

Induction Heating for Roll Hardening

When it comes to heating in industries, professionals tend towards induction heating systems due to their reliability including the metal industry. It is the non-contact heating method of electromagnetic induction method for heating metal. Electromagnetic induction heating has a great selectivity option in induction heating systems. Induction heating allows heating only areas of interest, making this system more reliable. In this article, we will discuss the induction heating system, covering all necessary parameters.

Industrial Induction Heating Systems for Metal Industries:

Induction heating and traditional heating system differ in their operations. Traditional heating depends on radiation to apply heat to a metal while industrial induction heating system uses an electromagnetic induction system to provide heat. That’s what makes it more efficient in industry for metal heating.

Induction inductions for metals provide versatility in the operation of converting into new shapes and sizes. Industrial heating system for metal industries uses induction heating for billets, bars, tubes, wires, and sheets of metal.

Temperature control in this process allows this process to make efficient and mechanically strong final product. Precise temperature control provide precise heating used for annealing, hardening, tempering. Furthermore, an industrial induction heating system is quite safer in use as compared to traditional heating.

Working Principle:

When current flows in a conductor, a magnetic field around the conductor is produced. The current direction is responsible for the magnetic field direction.We can understand with an example that 60Hz frequency and 550kHz current will change the direction of the magnetic field by 60 times and 550,000 times respectively.

Showing Joule’s law and its formula of heat
Showing Joule’s law and its formula of heat

After placing the metal in the magnetic field, a current will be induced in the metal. The current produced in the metal is opposite in the direction of the current produced in the coil. So we can control the current in the metal by controlling the coil in the coil.

Current in the metal will face its resistance in its way that will cause heat in the metal. This is called Joule’s law of heat. You can see in the following diagram that heat (Q) can be produced as the result of current ad resistance:

This is the working principle of induction heating systems for metal industries. More resistant materials give off more heat but with the help of induction heating it is possible to heat such vigorous materials.

Induction heating and Traditional Heating:

Let’s discuss some key differences of induction and traditional heating system in industrial induction heating system.

Induction Heating System Traditional Heating System
Do not require hot surfaces or flames. It is safer to implement in the heating industry. It may cause injuries or risks by hot flames or hot surfaces.
Induction heating systems require less time to achieve a desired product. It needs more time and energy to fulfill metal heating.
Induction heating precise heating ad control of temperature. These two parameters are not present in traditional heating systems.
Use electromagnetic induction to provide heat to a metal. Traditional heating use convention or radiation to provide heat to a metal.
More reliable for different sizes and shapes It may need additional setup for such desired shape or sizing.

Induction Heating Systems for Billets:

Induction Heating Systems for Billets forging application
Induction Heating Systems for Billets forging application

In the production of billets, induction heating provide necessary heating for forging, shaping, or rolling of metals. For example, we have to apply these cases for Aluminum, Copper or steel.

Induction heating system works on the same principle for billets. It works by using the electromagnetic induction method to provide heat to subjected metal. Induction heating systems provide heat to billets before converting them to new tubes, rods, or any other shapes. Electrical conductivity and magnetic permeability affect the choice of induction heating system.

Power consumption for this system is responsible for costand induction heating maintains a balance between the power efficiency and performance of the system.

Railway Component Hardening
Railway Component Hardening
Induction Billet Heater
Induction Billet Heater

 

 

 

 

 

 

Regular Maintenance of Induction Heating Machine:                 

To keep the induction heating machine, workers or caretakers must follow following best practices for better operation and maintenance of the industrial induction heating machine.

  • Check and try to maintain the cooling level to keep going with the heating machines
  • Perform electrical maintenance of the machine.
  • Inspect all working equipment within the machine which can include the power supply, heating coil, and cooling system.
  • Clean the machine to maintain its aesthetics and good working.
  • Follow manufacturer guidelines to go through with a machine in a good way.

Conclusion:

Induction heating systems offer various benefits in the metalworking industry with enhanced efficiency, selectivity, and versatility. One needs to understand the working principle and its application in the manufacturing industry. Industrial heating systems for metal industries depend on different factors to optimize the maximum efficiency of induction heating.

As the metal industry is evolving, the future of induction heating is more advanced in its operation and performance with advancedtechnologies.