Application: Preheat & Postheat
Application Objectives: A steel manufacturer is looking to replace current torch preheating technology with induction heating to improve quality and reliability of the processed products. Technical requirements are to preheat cylindrical parts by reaching an optimum temperature of 230 oC and preheat within a total of 5 minutes. The challenge is to reach and keep the desired temperature for the time slot evenly and uniformly.
Equipment: UltraHeat W Series – 5-15 kW with UBraze Handheld and Automation System
Additional Equipment Used: dual-color pyrometer 100-2000°C range; Embedded system thermoregulator.
Materials: Cylindrical carbon steel parts with inner diameter of 120 mm and outer diameter of 140 mm, length of 300 mm
Process:
First, we had to evaluate the overall time needed for the heat to conduct through the pipe wall to choose the right equipment set up – heat station, inductor, and power supply model. In addition, we had to run tests and evaluate the feasibility as well as provide maximum rotation speed for the details.
Simulations for the detail that we received have been prepared to give us a better understanding of the required time for the heat distribution.
Tests with our 15kW lab system were performed. According to the results, the system can reach the required temperatures very quickly. With a suitable coil design, we can even speed up the heating process.
According to our tests, we can heat up a 40 mm spot in 5 seconds. This gives us a speed of around 8mm/s heating speed, or 480mm/min, which is the maximum speed that can be achieved with 9kW. Of course, the initial heating (the first spot) takes 5-6 seconds. With our SOLO 16 system and a proper coil design, the maximum heating speed will be at least 903 mm/min.
Conclusions and recommendations: The systems we recommend are either SOLO 12 or SOLO 16. As of the uniformity of the heating process, we realized the detail can be fully rotated up to 3 or 4 times so the temperature has enough time to distribute evenly. Slower heating speeds can also help to achieve uniformity.
Reference Info: AR 3464-7738
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