Application: Wire Heating with Induction 

Objective: A leading wire and cable manufacturer is exploring the transition to induction heating technology. They have provided us with samples for testing, aiming to replace their traditional oil/gas furnaces. The primary objectives are enhanced process control and a shift towards more environmentally friendly manufacturing practices.

We tested a sample of 302 stainless steel wire rod, measuring 0.369 inches (0.94 cm) in diameter. The challenge was to achieve a uniform heating cycle of 150-175°F (65-80°C) at a line speed of 27-35 feet per minute (8-11 meters per minute), with a maximum temperature limit of 250°F (121°C).

The goals of our application testing included identifying optimal process parameters, boosting efficiency with faster heating cycles, ensuring consistent quality and repeatability, and enhancing safety and energy conservation.

Industry: Wire & Cable 

Equipment: UltraFlex Solo – Induction Heating System 

Process: Our expert application engineering team conducted a series of three tests using varied power settings. Initially, the induction heater was set at 5 kW and 10 kW for the first and second tests, resulting in heat cycle times of 2.5 seconds. However, the temperatures reached – 120°F (49°C) and 170°F (77°C) – were below our target.

In our third attempt, we increased the power supply of the induction heater to 15 kW, maintaining the cycle time at 2.5 seconds. This adjustment successfully achieved the desired temperature of 225°F (107°C).

Benefits: Induction heating for wires and cables offers numerous benefits. It’s an increasingly popular choice in industries seeking to upgrade outdated equipment and invest in sustainable, green technology. This approach significantly enhances energy efficiency and worker safety while boosting overall productivity.

Reference Info: Application Note 3463-7313

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