Engergy Efficient Industrial Induction Heating Equipment For Automotive Manufacturing

WHAT IS INDUCTION HEATING:

Induction heating is a process which is used to bond, harden or soften metals or other conductive materials. For many modern manufacturing processes, induction heating offers an attractive combination of speed, consistency and control.

In the most common heating methods, a torch or open flame is directly applied to the metal part. But with induction heating, heat is actually "induced" within the part itself by circulating electrical currents.

Induction heating relies on the unique characteristics of radio frequency (RF) energy - that portion of the electromagnetic spectrum below infrared and microwave energy. Since heat is transferred to the product via electromagnetic waves, the part never comes into direct contact with any flame, the inductor itself does not get hot, and there is no product contamination. When properly set up, the process becomes very repeatable and controllable.

INDUCTION HEATER POWER REQUIRMENT:

THE TECHNICAL PARAMETERS OF THE INDUCTION HEATER:

APPLICATIONS IN AUTOMOTIVE MANUFACTURING:

Induction heating machines are used in the manufacture of many parts along the automotive drive train - including CV joints, tulips, gears, steering racks, and wheel hubs. Induction technology is also used to produce large body and engine parts such as rocker arms, cam shafts, valves, connecting rods, banding, crank shafts, and starting rings. Finally, shock absorber components are hardened and formed using induction.

Induction heating machines are increasingly used for automotive manufacturing processes such as:

• Bonding - Components of automotive assemblies such as doors, bonnets, liftgates, decklids, fenders, and roof panels can be bonded together by heating structural adhesive material that has been previously applied.
• Hardening - One of the advantages of induction heating is that it can be directed to specific areas of the part with great accuracy. Most hardening operations treat the outer part surface. The treatment can be done in two different ways: either static or progressive (by scanning).
• Tempering - While traditional tempering systems heating the parts at relatively low temperatures (from 150 to 700ºC) for a relatively long heat and cooling cycle, induction tempering permits the use of higher temperatures and shorter heating/cooling cycles.
• Annealing - In contrast to hardening, the annealing process involves a relatively slow heating step followed by gradual cooling. Annealing is used when the material must be softened as much as possible; tempering softens the metal but not to the full extent possible.
• Brazing - An induction brazing machine quickly delivers highly localized heat to minimize part warpage and distortion. Brazing in a controlled vacuum or in an inert protective atmosphere can significantly improve overall part quality and eliminate costly part cleaning procedures.

THE ADVANTAGES OF THE INDUCTION HEATING:

Maximized Productivity

• Production rates can be maximized because induction works so quickly; heat is developed directly and instantly (>2000º F. in < 1 second) inside the part. Startup is virtually instantaneous; no warm up or cool down cycle is required. The induction heating process can be completed on the manufacturing floor, next to the cold or hot forming machine, instead of sending batches of parts to a remote furnace area or subcontractor. For example, a brazing or soldering process which previously required a time-consuming, off-line batch heating approach can now be replaced with a continuous, one-piece flow manufacturing system.

Improved Product Quality

• With induction, the part to be heated never comes into direct contact with a flame or other heating element; the heat is induced within the part itself by alternating electrical current. As a result, product warpage, distortion and reject rates are minimized. The vacuum brazing process is often utilized when maximum product quality is essential; the part can be isolated in an enclosed chamber with a vacuum, inert or reducing atmosphere to eliminate the effects of oxidation.

Environmentally Sound

• Induction heating systems do not burn traditional fossil fuels; induction is a clean, non-polluting process which will help protect the environment. An induction system improves working conditions for your employees by eliminating smoke, waste heat, noxious emissions and loud noise. Heating is safe and efficient with no open flame to endanger the operator or obscure the process. Non-conductive materials are not affected and can be located in close proximity to the heating zone without damage.

Reduced Energy Consumption

• This uniquely energy-efficient process converts up to 90% of the energy expended energy into useful heat; batch furnaces are generally only 45% energy-efficient. And since induction requires no warm-up or cool-down cycle, stand-by heat losses are reduced to a bare minimum. The repeatability and consistency of the induction process make it highly compatible with energy-efficient automated systems.

Optimized Consistency

• Induction heating eliminates the inconsistencies and quality issues associated with open flame, torch heating and other methods. Once the system is properly calibrated and set up, there is no guess work or variation; the heating pattern is repeatable and consistent. With modern solid state systems, precise temperature control provides uniform results; power can be instantly turned on or shut off. With closed loop temperature control, advanced induction heating systems have the capability to measure the temperature of each individual part. Specific ramp up, hold and ramp down rates can be established & data can be recorded for each part that is run.

OUR SERVICES

Pre-sale service.

• Inquiry and consulting service
• Recommend the most suitable for our customers according to their requirements
• Sample testing support
• Working videos available
• View our factory

In-sale service.

• Strictly manufacture the machine, according to relevant technical standards.
• Take run test, according to relevant equipment test run regulations.
• Strictly check up the machine, before delivery
• Delivery on time.

After-sale service.

• Warranty time: 1year Warranty.
• Within warranty all parts are free for customer, any fault caused by non-artificial reason, any quality problems such as design, manufacture, or procedure occurs, We shall provide replacement parts after detecting the faults.
• If any big quality problems occurs out of the guarantee period, we will send maintenance
• Technician to provide visiting service after checking with the customer and charge for a favorable price.
• We will provide a lifetime cost price to the buyer with the materials and spare parts used in system operation, equipment maintenance.
• The above mentioned are only basic aftersale service requirements,we will make more promises related to quality assurance and operation guarantee.