Induction Forming Seminar

•

4 j'aime•1,804 vues

PlasticWeld Systems, Inc.

Detailed presentation on the fundamentals of using induction heating to form tips on polymer tubes.

Santé & Médecine Technologie Business

PlasticWeld Systems Precision Catheter Manufacturing Equipment ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Principle of Operation of Induction Generators ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Principle of Operation of Induction Generators

Principle of Operation of Induction Generators Coil cross-section Flux field

Principle of Operation of Induction Generators More heat Less heat

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Principle of Operation of Induction Generators Shows some solid state components used in the HPS-10 and MK-25 generators. The IGBT as used in the MK-25 functions in the lower frequency range whereas the MOSFET transistor is used in the HPS-10 so we can use the high frequency range.

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Various Coil Configurations Coil Design & Theory

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Die Configuration & Heat Application Theory

Die Configuration & Heat Application Theory ,[object Object]

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Tipping Die Material ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Contenu connexe

Tendances

Recognizing and Eliminating Flux Concentrator Failures

Fluxtrol Inc.

Chapter 7: Fluxtrol Induction Heating Case Studies and Success Stories

Fluxtrol Inc.

By Dr. Valentin Nemkov - Fluxtrol Inc. Magnetic flux controllers are widely used in induction heating systems for concentration, shielding or redistribution of the magnetic field which generates power in the part to be heated. Controllers, made of Soft Magnetic Composites (SMC), provide accurate heat pattern control, improve parameters of inductors and performance of the entire installation. In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic control can provide large energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution for enhancement of the metallurgical processes. Due to the diversity of applications, service conditions of controllers are very different including very severe cases. Mechanical, magnetic, electrical, thermal and other properties must be considered in design and application of SMC. This article describes properties and performance of SMC typically used in induction heating technology. Several presented case stories are based on more than 20 years of R&D and practical experience of scientists and practitioners at Fluxtrol, Inc. Presented material may be interesting not only for induction heating community but also for all people using AC magnetic fields in technological processes.

Magnetic FLux Control in Induction Systems - Fluxtrol Heat Processing Paper

Fluxtrol Inc.

2 Fluxtrol Sample Induction Heating Installations

Fluxtrol Inc.

Chapter 1a: Fluxtrol Basics of Induction Techniques Part 1

Fluxtrol Inc.

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Fluxtrol Inc.

Induction heating applications

ramavatarmeena

Specification and Use of a Flux Concentrator

Fluxtrol Inc.

http://fluxtrol.com ABSTRACT. Induction heating is the most progressive method for brazing of squirrel cage (SC) type rotors of electric motors. Frequencies from 3 to 10 kHz are typically being used for brazing of relatively large rotors (diameter more than 200 mm). If the ring thickness exceeds its height, flat single or two-turn inductors with concentrator are located under the ring instead of the round coil surrounding the ring. The rotor is standing on the top of the coil providing high pressure onto the joint components; a gap between the coil and ring is minimal and constant during the heating process. This study describes a modified system with concentrator made of magnetic composite Fluxtrol 100. Frequency was much higher (around 50 kHz) than traditionally used (3-10 kHz). Electromagnetic and thermal coupled simulation with Flux 2D used to compare the process parameters and temperature distribution dynamics at 3 and 50 kHz. It was found that at higher frequency the brazing quality and time are approximately the same as at lower frequency. Electrical efficiency is slightly higher at 50 kHz while the coil current is significantly lower. Computer simulation at different powers showed that for a larger rotor the minimum required power is 70-75 kW. At lower power brazing time quickly increases and at 50 kW reaches 16 min instead of 5 min at 75 kW. Electrodynamic forces between the coil and rotor at 75 kW equal to 250 N at 50 kHz and almost 950 N at 3 kHz. Thermal simulation of the coil proved that the maximum temperature of Fluxtrol 100 concentrator is below 200 C, which is acceptable for this material. Experimental and then industrial tests confirmed the results of simulation.

SIMULATION OF INDUCTION SYSTEM FOR BRAZING OF SQUIRREL CAGE ROTOR

Fluxtrol Inc.

High frequency induction heating

silviusoft

MAGNETIC FLUX CONTROLLERS are materials other than the copper coil that are used in induction systems to alter the flow of the magnetic field. Magnetic flux controllers used in power supplying components are not considered in this article. Magnetic flux controllers have been in existence since the development of the induction technique. Michael Faraday used two coils of wire wrapped around an iron core in his experiments that led to Faraday’s lawof electromagnetic induction, which states that the electromotive force (emf) induced in a circuit is directly proportional to the time rate of change of the magnetic flux through the circuit. After the development of the induction principle, magnetic flux controllers, in the form of stacks of laminated steel, found widespread use in the development of transformers for more efficient transmission of energy (Ref 1, 2). Magnetic cores gained widespread use in the transformer industry because they increased the amount of magnetic flux produced with the same alternating current. The higher the magnetic flux, the higher the emf, which results in an increase in energy transfer efficiency from the primary winding to the secondary winding. Similar to transformers, magnetic cores were used on early furnaces for induction melting (Ref 1, 2). The benefits of magnetic flux controllers vary depending on the application. For induction heating, magnetic flux controllers can provide favorable and unfavorable paths for magnetic flux to flow, resulting in increased heating in desired areas and reduced the heating in undesirable areas, respectively.Magnetic flux controllers are not used in every induction heating application, but their use has increased (Ref 3, 4). Copyright 2014, ASM International, www.asminternational.org. This article was published in ASM Handbook, Volume 4C: Induction Heating and Heat Treatment and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this article for a fee or for commercial purposes, or modification of the content of this article is prohibited.

Magnetic Flux Controllers in Induction Heating and Melting by Robert Goldstei...

Fluxtrol Inc.

Chapter 1B: Fluxtrol Basics of Induction Techniques Part 2

Fluxtrol Inc.

Feasibility of making lightweight powertrain products with hot hydroforging of steel/low density material hybrid billets is explored. A bimaterial billet is designed such that a steel wall encloses a low density core 100%. Furthermore the low density core is selected among the materials that have lower melting or softening temperature than steel such as aluminum and glass. In hot hydroforging the bimaterial billet is heated to 1000-1200 C range similar to the conventional hot forging of steel. However, in hot hydroforging the core is in liquid or viscous state while steel shell is in solid state similar to the conventional hydroforming. During hot hydroforging the viscous/liquid core has negligible resistance to flow thereby providing a uniform hydrostatic pressure inside the steel and enabling a uniform deformation of the solid steel wall.

Hot Hydroforging of Lightweight Bilateral Gears and Hollow Products

Fluxtrol Inc.

Induction Heating in the Powertrain Industry

Fluxtrol Inc.

Computer Simulation of Induction Heating Process

Fluxtrol Inc.

With the use of good design practices, one can improve coil longevity and improve production quality. By eliminating failure points in the initial design, proper material selection, improved cooling and proper magnetic flux control, induction tooling life can be increased. Computer simulation has been proven to be an effective tool for predicting not only electromagnetic parameters of a designed system, but also heat patterns in a given part and in the induction coil itself. When a coil has magnetic flux controllers present, their influence may also be predicted by computer simulation. With an extensive library of published case studies in induction coil design and performance evaluations, we are confident with the use of these tools and proper coil geometries and implementation, production life and quality can be improved on most induction heat treating inductors. These design practices have been used by the authors for over 20 years with proven results. A case is examined of a CVJ stem hardening coil, in which the principles discussed can be applied to most other hardening coils.

Fluxtrol's "Best Practice for Design and Manufacturing of Heat Treating Induc...

Fluxtrol Inc.

http://fluxtrol.com It is well known that performance of some induction systems may be significantly improved by application of magnetic flux controllers. They are used to concentrate, shield and/or redistribute the magnetic field which generates power in the part. Theoretical and practical evidences are presented in the paper, which show that there is still significant potential for improvement in innovative and traditional induction technologies due to magnetic flux control. Utilizing magnetic flux controllers in heat treating processes results in excellent heat pattern control and improvement of parameters of inductors and entire power delivery systems. In melting systems, especially in the case of vacuum furnaces, cold crucible and other specialty furnaces, the magnetic control can provide energy savings, magnetic field shielding, shorter melting cycles and optimized field distribution for metallurgical processes. Comparison of different groups of materials for magnetic flux control (laminations, ferrites and Soft Magnetic Composites, aka Magnetodielectrics) is also presented in the paper. Several examples of magnetic flux control illustrate the presented material based on more than 20 years of R&D and practical experience of scientists and practitioners at Fluxtrol Inc.

MAGNETIC FLUX CONTROL IN INDUCTION INSTALLATIONS

Fluxtrol Inc.

http://fluxtrol.com Cold Crucible Furnaces (CCFs), widely used in multiple special applications of melting metals, oxides, glasses and other materials [1], are essentially 3D devices and their modeling is a complicated task. Multiple studies of CCFs have been made for their optimization, but their electrical efficiency is still low; for metals approximately 25-30% and even lower. Fluxtrol, Inc., made an extensive study of electromagnetic processes of CCFs using computer simulation and laboratory tests. This study showed that electrical efficiency of CCFs may be strongly improved by means of optimal design of the whole system with use of magnetic flux controllers. Theoretical results had been confirmed by laboratory tests on mockups and by industrial tests with real melting processes. The presentation contains a description of the computer modeling procedure and major findings. They form a basis for optimal design of electromagnetic systems of CCFs.

MODELING AND OPTIMIZATION OF COLD CRUCIBLE FURNACES FOR MELTING METALS

Fluxtrol Inc.

Induction Heating Fundamentals

Brett Daly

Chapter 5: Magnetic Flux Control for Induction Heating Systems

Fluxtrol Inc.

Tendances (20)

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Chapter 7: Fluxtrol Induction Heating Case Studies and Success Stories

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Induction Heating Fundamentals

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Project-Induction.pptx

jaegar .

This paper deals with high energy consuming induction holding furnace. The improved version of coil design along with additional electrical interlocks and alarm, modified hydraulic controls, strengthening mechanical structures and energy saving proposals at holding furnace fume extraction system ensures trouble free operation of furnace and hence continuity of production at all the planned plant operational days. This project involves in purchasing of D-section copper extruded coil from Europe–Switzerland for its extended length from existing 3 meters long to 9 Meters which enables in reduction of coil joints. The performance of the holding furnace has improved in terms ofits energy consumption per ton of liquid metal. The payback period for the estimated investment will be less than 2 years.

Energy conservation at high power consuming holding furnace with modified coi...

International Journal of Power Electronics and Drive Systems

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The heat sinks are used in electronic systems to remove heat from the chip and effectively transfer it to the ambient. The heat sink geometry is designed by the mechanical engineers with the primary aim of reducing the thermal resistance of the heat sink for better cooling in the electronic systems. Due to the proximity of the heat sink with the ICs, the RF fields created by RF currents in the ICs/PCBs gets coupled to heat sinks. Hence, the coupled RF current can cause radiated emission. This radiated noise from the device can couple and disturb the functioning of the nearby electronic systems. Also this radiated emission from the device poses a problem to the system compliance with respect to EMI/EMC regulations. The international EMI/EMC standards require the radiated emission from the electronic devices to be kept below the specified limits. As a result the design of Heat Sink is very important factor for the efficient operation of the electronic equipment. In this project design optimization of a Heat sink in a Power amplifier is performed to reduce the weight and size .Power amplifier is electronic equipment mounted in an army vehicle. The power modules inside the amplifier generates a heat of 1440 Watts and a temperature of 140 0c.Two Heat sinks are used to dissipate the heat generated inside the equipment and maintain a temperature of less than 850c. The existing heat sink which is being used is weighing around 10.3kgs and height of 51mm; as a result the unit is very robust. The objective of my project is To design & optimize the heat sink to reduce the weight and size. The optimized heat sink should also dissipate heat generated by power modules and maintain a temperature of less than 850c inside. To achieve the design a steady state thermal analysis will be performed on the heat sink and plot the Temperature distribution on the fins. Based on the above analysis results we will increase/decrease the number of fins, thickness of fins, and height of fins to reduce the weight of the heat sink. We will perform CFD analysis of the power amplifier by mounting the optimized heat sink and plot temperature, pressure and velocity distribution in the power amplifier enclosure. Efforts are made to optimize temperature, pressure and velocity distribution in the power amplifier enclosure by reorienting the power modules in the enclosure. UNIGRAPHICS software is used for 3D modeling SOLID WORKS FLOW SIMULATION software is used for thermal and CFD analysis.

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A very useful method of formulating the Total Thermal Resistance of ordinary mesa structure of DDR IMPATT diode oscillators are presented in this paper. The main aim of this paper is to provide a 2D model for Si and SiC based IMPATT having different heat sinks (Type IIA diamond and copper) at high power MMW frequency and study the characteristics of Total thermal resistance versus diode diameter for both the devices. Calculations of Total thermal resistances associated with different DDR IMPATT diodes with different base materials operating at 94 GHz (W-Band) are included in this paper using the author’s developed formulation for both type-IIA diamond and copper semi-infinite heat sinks separately. Heat Sinks are designed using both type-IIA diamond and copper for all those diodes to operate near 500 K (which is well below the burn-out temperatures of all those base materials) for CW steady state operation. Results are provided in the form of necessary graphs and tables.

A 2D MODELLING OF THERMAL HEAT SINK FOR IMPATT AT HIGH POWER MMW FREQUENCY

cscpconf

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