Of course, induction heating should be the main consideration for the heat source required for your current or upcoming remanufacturing heating operation.
Induction heating technology has been commercialized for more than 100 years, but for those who are not familiar with its application, it is still considered "new technology". Although it is a proven and mature thermal technology, there is still a certain "mystery or art" in the application of this applied science.
Induction is most commonly used in melting, forging, and precision heat treatment applications. In addition, induction heating is widely used in various metal joining techniques, such as brazing, soldering, heat shrink fitting, and adhesives. Most induction heating systems are sold to OEM car and off-road engine manufacturers with the goal of manufacturing new engines and transmission system components and extending their service life.
In the past decade, induction heating has been a useful technology for powertrain remanufacturing operations and continues to be popular in the industry worldwide. Sales and demand continue to increase the demand for the use of induction heating systems for various transmission system remanufacturing applications. These components include but are not limited to: cylinder heads, connecting rods, gearboxes, differentials, gears, bearings, pulleys, ring gears, flywheels, etc.
The information provided in this white paper is intended to illustrate a better understanding of induction heating technology, the advantages it creates through unlimited functions and versatility, and its proven record of generating high return on investment. Some of these benefits include increased core retention, reduced waste, expanded production, reduced labor content, reduced energy consumption, reduced consumables, improved employee safety and ergonomics.
Michael Faraday proved the theory of induced current generation by electromagnetic induction in 1831. Dr. Edwin Finch Northrup first commercialized this technology for industrial heating applications in 1918.
Induction heating is a thermal process in which conductive materials are placed in a changing magnetic field and heated by hysteresis (magnetic materials only) and/or induced current (all conductive materials). The changing magnetic field is generated by high frequency alternating current (AC) passing through electrical windings (coils/inductors). Induction heating is a non-contact heating method, which is very fast and efficient compared to other heating techniques used for remanufacturing. The energy conversion efficiency can be as high as 90%. The heating time is measured in seconds, and there is no burning or physical contact with the heated part.
It is important for interested users to consult a qualified induction heating supplier to help specify the induction heating system. There are many variables when choosing an induction heating system, such as power (kW), operating frequency (kHz), heating inductor design, and process control methods.
Many induction heating system parameters are affected by many variables in the manufacturing process, such as component alloy, component size, allowable heating time, target temperature, maximum temperature, and material handling limitations. It is recommended that process engineers review the potential applications of induction heating to ensure a successful, reliable and repeatable process.
A heating inductor (coil) is an electrical winding through which alternating current passes to generate an electromagnetic field with a specific pattern, which is used to heat conductive objects.
Many people imagine a heating inductor as a simple spiral winding, made of copper tube, surrounding the part to be heated. Although this will be a
There are still many considerations for the form of the inductor. Heating inductors can be made of hollow copper tubes, solid rods, flexible cables, machined blanks, and can even be 3D printed from copper powder. The design of the inductor depends on the process requirements, budget, and the user's ability to build the inductor. Copper is the material of choice for inductors because of its high electrical conductivity (low power loss), high thermal conductivity (easy to cool with water) and relatively low cost. Most inductors are water-cooled due to the reflected heat of the components and the extremely high current flowing in the inductor (usually 1000 amperes).
The inductor is the most important part of the induction heating system. Inductors can be designed in many different configurations, such as solenoids, hairpins, pancakes, lateral, ID, channels, flip caps, and machined/3D printed contours. Only the solenoid inductor surrounds the part (Figure 1). It is a common misconception that the inductor must completely surround the part. The fact is that the inductor can be heated from outside, inside, one side, both sides or even 3 sides. Inductors are usually shaped according to the shape of the part and/or the area of the part to be heated. The style of the inductor affects the efficiency. For example, the power required to heat an inductor internally is approximately twice that of a solenoid inductor.
The gap between the heated part and the inductor, called the coupling gap, also affects efficiency. As the coupling gap increases, the efficiency decreases. In the process development stage of your application, it is important to consult an inductor design expert as early as possible so that the process has the greatest chance of success.
Inefficient inductors use too much power, have poor repeatability, require post-processing of parts, or may not work at all. The induction heating process is only as good as the inductor used for this process.
The main design attributes of high-quality inductors are as follows:
For example, the design and manufacture of induction valve seat heating inductors comply with very strict machine tool tolerances to provide precise alignment and precise heating zones. Therefore, the heat is limited to only the valve seat area (Figure 2a) to prevent thermal damage to the female hole of the valve seat cover. Like most inductors, they are water-cooled and equipped with specific alignment and spacing functions to eliminate guesswork in the process and simplify the operator's procedures.
This type of inductor (Figure 2b) is equipped with a quick replacement function, supports different inductor geometries, and can be replaced within a few seconds according to the brand and model of the head being processed. The durability of this design and heat-resistant materials allow the use of a single induction valve seat heating sensor to heat thousands of seats.
Modern control can be integrated into the entire induction heating process to accurately and consistently control the heating process. Modern induction heating systems use a large number of microprocessors to provide data on process performance characteristics.
Induction heating is not only very controllable and repeatable, but also very predictable.
Using finite element analysis (FEA) software and proprietary simulation software packages, induction OEMs can accurately predict the heating mode, temperature rise, temperature distribution, stress, strain, and even metallurgical changes of a part before a single part is physically heated (Figure 3).
It is easy to see that induction heating offers many advantages over other heating methods, including accuracy, speed, control, and energy efficiency. However, induction is only part of the heating process. Although electromagnetic induction provides excellent thermal control, it can only be as accurate as its ability to control other variables of each process (such as part tolerance, part location, part cleanliness, part material, process consistency, and several other factors) And repeatable.
Induction heating OEMs such as Ajax TOCCO Magnethermic Corporation provide customers with laboratory tests on their actual production parts. Customers can send parts for all types of induction heating applications and experience the mature results of the induction heating process.
Some obvious advantages of using our induction heating equipment are: repeatability, reliability, quality, safety and speed.
In addition, remanufacturing users have obtained a good return on investment, and due to labor savings, safety, efficiency, and even lower medical insurance costs, most users have been able to justify the cost.
Why choose induction heating for your REMAN application?
Induction heating does not burn traditional fossil fuels. This is a clean and pollution-free process, however, in the past 100 years, green sensing seems to be the biggest little secret. Induction has always been a "green technology".
The induction heating system is not harmful to the environment and improves the working conditions of employees by eliminating smoke, waste heat, harmful emissions and loud noise.
Compared with batch furnaces that are usually only 45% energy efficient, this unique energy-saving process can convert up to 90% of the energy into useful heat. Since induction does not require preheating or cooling cycles, standby heat loss is reduced to a minimum. The repeatability and consistency of the induction process make it highly compatible with energy-saving automation systems.
The remanufacturing industry is one of the more prominent industries that embody green development. According to the RIC (Remanufacturing Industry Council), Reman restores previously sold, worn or non-functional products or components to a "like new" or "better than new" state, and guarantees their performance level and quality.
Very similar to the induction heating community, the remanufacturing industry also has a closely-connected organization and association group on a global scale.
Also similar to induction technology, some of the main benefits of remanufacturing include saving materials, reducing energy consumption in the manufacturing process, reducing waste, and obtaining a higher return on investment by purchasing products of the same quality at a lower price.
Induction heating technology has proven to be successful in many applications in the remanufacturing industry. Examples of these innovative heating applications include:
Induction heating for disassembly/disassembly
One of the most popular remanufacturing applications is induction heating for disassembly of valve seats. Ajax TOCCO Magnethermic provides an engineering solution for this application, which is internally called Inductive Valve Seat Removal (IVSR). The engineered IVSR system provided by Ajax TOCCO Magnethermic revolutionized the heavy-duty engine remanufacturing industry, especially the task of removing the press-in valve seat from the engine cylinder head. The Ajax TOCCO process involves rapid heating of the press-in valve seat in a matter of seconds. Once the seats have cooled, they shrink and can be easily removed with a few simple modified hand tools (Figure 4). In some cases, the seat can be removed with just a gloved hand.
Dozens of IVSR systems have been provided to major original equipment manufacturers and the world's leading engine remanufacturing companies.
Seats of various sizes in ferrous and non-ferrous cylinder heads (Figure 5-7) have been successfully heated, shrunk and extracted using the IVSR process. The IVSR system is relatively compact, transportable (Figure 8) and adaptable, allowing the process to be easily transported to the place where it is needed.
Induction heating is a very controllable, repeatable and scalable process. According to process requirements, a temperature rise of several degrees to several thousand degrees can be achieved within a few seconds or within a specified time.
Induction heating technology can be used to obtain temperatures that are not easily reached by torches, resistors, and/or furnaces. Unlike combustion or radiant heating methods, induction heating is not affected by environmental changes such as dew point, airflow, ambient temperature or pressure.
Induction can be very selective, heating only a small part (a few millimeters) of the part, or it can heat the entire assembly in a single-piece part stream or continuous conveyor production.
Induction is very suitable for heating parts of various geometries.
The energy efficiency of induction can reach 90%. The heat is turned on and off instantly, so no power is wasted during standby or production delays.
The benefits of using induction heating technology in the remanufacturing industry are limitless. Encourage interested parties to constantly look for new potential applications. Replace the "blue wrench" (flashlight) with an induction heating system to increase your profits.
The induction heating system is movable, and it can be adapted to various types of applications only by changing tools in a short time. Induction heating should of course be the main consideration for the heat source required for your current or upcoming Reman heating operation.
Contact: John Lormin, field sales engineer, low-power products, Ajax TOCCO Magnethermic – 248-691-2299 or [email protection]
Technology Center: Cleaning Equipment in Today's Stores
Components: the speed of air engine technology
Store Solution: Store Solution October 2021
Technology Center: EMCO Gears: Bringing racing transmissions to the streets
ByEngine Builder staff on October 14, 2021
ByEngine Builder staff on October 14, 2021
Product: Romi C 1800H Heavy Duty Lathe
Engine News: American Recycling Day: How to Dispose of Engine Oil Correctly
Engine News: Lucas Oil Products expands partnership with Monster Jam
Engine News: Champion racer Bob Bondurant dies at the age of 88
Product: Hays Billet Steel SFI certified flywheel, suitable for Gen III Hemi
2,000 horsepower GT500 short block
Compound turbocharged 5.9L 12-valve Cummins engine
The third-generation twin-turbocharged 5.0-liter Coyote engine