Influence of Magnetic Flux Controllers on Induction Heating Systems

http://fluxtrol.com Influence of Magnetic Flux Controllers on Induction Heating Systems

Technologie Business

Influence of Magnetic Flux Controllers
on Induction Heating Systems, Computer
Simulation and Practice

Robert T. Ruffini, President
Fluxtrol Manufacturing, Inc. Auburn Hills, MI

Dr. Valentin S. Nemkov, Chief Scientist; Robert C. Goldstein, Research Engineer
Centre for Induction Technology, Inc. Auburn Hills, MI

Overview
• Magnetic Flux Control in Induction Heating
• Magnetic Flux Controller Application
Technique
• Examples of Induction Coils with Magnetic
Flux Controllers
• Conclusions
• Robot Guided Induction Heating
Application

Technological Effects of MFC
Application
• Improved induction coil efficiency
• Better utilization of the workpiece power
• Magnetic field and heat pattern control
• Protection against unintended heating
• Improved power supplying circuitry
performance
• Elimination of external magnetic fields

Materials for Magnetic Flux
Control
• Laminations
2
Laminations

1.6

MDM's

• Ferrites 1.2

Flux Density (T)
0.8

• Magnetodielectric 0.4
Ferrites

Materials (MDMs)
0
0 50 100 150 200 250
Magnetic Field Strength
(A/cm)

B-H Curves for MFCs

Considerations for MFC
Selection
• Relative magnetic permeability
• Operating frequency
• Core Losses
• Thermal resistance
• Ease of installation and removal
• Machinability
• Electrical resistivity
• Chemical resistance
• Cost

Typical properties of MDM’s
• Operating frequency: 50 Hz-5 MHz
• Temperature resistance: 150 - 350 C
• Initial relative permeability: 10 - 65
• Maximum permeability: 10 - 150
• Saturation flux density: 0.3 - 1.6 T
• Electrical resistivity: 100-10^7 Ohm-cm

Magnetic Permeability of
MDM’s for Induction Heating
150

125

100

Fluxtrol A
Permeability

75

50
Fluxtrol A'

25 Fluxtrol B
Ferrotron
0
0 50 100 150 200
Magnetic Field Strength
(A/cm)

How to Apply MDM’s to Induction
Heating Coils
• Epoxy/Glue/Adhesive MFC to Copper Coil
– Prepare copper surface by removing machining oil or residual
quenchant
– Use thermally conductive, electrically non conductive epoxy
– Use epoxy with high temperature and thermal shock resistance
• Mechanically Fasten
– Soft solder or braze a brass bolt to copper inductor and drill clearance
hole in MFC
– Use a thermally conductive grease between copper coil and MFC
• Soft Solder (Fluxtrol A)

Camshaft Lobe Sintering Power
InductorTM

Conclusions
• Magnetic Flux Controllers Are an Important
Part of the Induction Technique
• Examples of Induction Heating Coils with
MDM controllers applied were shown
• Computer Simulation Can Accurately
Predict the Performance of Magnetic Flux
Controllers

Robot Guided Induction Scanning
Application Demonstrates:

1. The ability to treat complex shape parts with induction
robotic technique
2. Modern induction equipment suitable for robotic
scanning
3. Ability of computer simulation to predict the results of
heating
4. Demonstration of the magnitude of magnetic flux
controller influence

Demonstration Stand

1. Workpiece - S-shaped 1/2” thick steel plate water-
cooled on the back side
2. Specially designed hair-pin coil with Fluxtrol A
magnetic flux controller applied
3. ABB industrial robot
4. Hand-hold coaxial transformer with a flexible cable
(EFD)
5. EFD power supply Minac: 30 kW, 10 - 25 kHz
6. Close loop cooling system (Dry Coolers, Inc.)

Induction Coil Comparison

Coil without a concentrator Coil with Fluxtrol A
concentrator

Induction Coil with Magnetic
Flux Controller

Robot Guided Induction Scanning
Conclusions
• Magnetic Flux Controllers Make a Dramatic
Effect on Hair-Pin Coil Performance
• Computer Simulation Allows the Designer
Accurately Predict the System Parameters and
Heating Results
• Robotic Scanning Systems Can Be Used
Effectively in Flexible Production Line

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Design and Fabrication of Inductors for Induction Heat Treating

In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling. What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.

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