This listing is for a brand new 10KW high frequency 100-500KHz induction heater (item# IHG10). Note: This model only available in 220 volt single phase.
IHG series 100 kHz to 1100 kHz high frequency induction heaters are among the latest products developed by Across International. They can quickly heat most metals that other frequencies can not heat efficiently, like aluminum and metal powders. And uniquely they can heat parts from a distance. These heaters are the ideal tools for fine steel wires (such as those used in dentistry) annealing, small precision shaft quenching, hard alloy saw blade brazing and metal powders melting.
heating does not involve the external application of heat but rather
the internal generation of heat in the workpiece itself. This process
dispenses with long heating periods and enables the limited introduction
of heat in a local and precisely timed manner, thus achieving a high
degree of efficiency and maximum exploitation of energy. When compared
with conventional heating methods, induction heating achieves maximum
levels of quality and efficiency across a practically unlimited range of
basic principles of induction heating have been understood and applied
to manufacturing since the 1920s. During World War II, the technology
developed rapidly to meet urgent wartime requirements for a fast,
reliable process to harden metal engine parts. More recently, the focus
on lean manufacturing techniques and emphasis on improved quality
control have led to a rediscovery of induction technology, along with
the development of precisely controlled, all solid state induction power
supplies. What makes this heating method so unique? 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. Since heat is
transferred to the product via electromagnetic waves, the part never
comes into direct contact with any flame, the coil itself does not get
hot, and there is no product contamination. When properly set up, the
process becomes very repeatable and controllable.
HOW INDUCTION HEATING WORKS
exactly does induction heating work? It helps to have a basic
understanding of the principles of electricity. When an alternating
electrical current is applied to the primary of a transformer, an
alternating magnetic field is created. According to Faraday’s Law, if
the secondary of the transformer is located within the magnetic field,
an electric current will be induced.
In a basic induction heating
setup, a solid state RF power supply sends an AC current through a
copper coil, and the part to be heated is placed inside the coil. The
coil serves as the transformer primary and the part to be heated becomes
a short circuit secondary. When a metal part is placed within the
induction coil and enters the magnetic field, circulating eddy currents
are induced within the part. These eddty currents flow against the
electrical resistivity of the metal, generating precise and localized
heat without any direct contact between the part and the coil.
IMPORTANT FACTORS TO CONSIDER
efficiency of an induction heating system for a specific application
depends on several factors: the characteristics of the part itself, the
design of the induction coil, the capacity of the power supply, and the
degree of temperature change required for the application.
METAL OR PLASTIC
induction heating works directly only with conductive materials,
normally metals. Plastics and other non-conductive materials can often
be heated indirectly by first heating a conductive metal susceptor which
transfers heat to the non-conductive material.
MAGNETIC OR NON-MAGNETIC
is easier to heat magnetic materials. In addition to the heat induced
by eddy currents, magnetic materials also produce heat through what is
called the hysteresis effect. During the induction heating process,
magnetics naturally offer resistance to the rapidly alternating
electrical fields, and this causes enough friction to provide a
secondary source of heat. This effect ceases to occur at temperatures
above the “Curie” point – the temperature at which a magnetic material
loses its magnetic properties. The relative resistance of magnetic
materials is rated on a “permeability” scale of 100 to 500; while
non-magnetics have a permeability of 1, magnetic materials can have a
permeability as high as 500.
THICK OR THIN
conductive materials, about 80% of the heating effect occurs on the
surface or “skin” of the part; the heating intensity diminishes as the
distance from the surface increases. So small or thin parts generally
heat more quickly than large thick parts, especially if the larger parts
need to be heated all the way through. Research has shown a
relationship between the heating depth of penetration and the frequency
of the alternating current. Frequencies of 100 to 400 kHz produce
relatively high-energy heat, ideal for quickly heating small parts or
the surface/skin of larger parts. For deep, penetrating heat, longer
heating cycles at 5 to 30 kHz has been shown to be most effective.
you use the exact same induction process to heat two same size pieces
of steel and copper, the results will be quite different. Why? Steel –
along with carbon, tin and tungsten – has high electrical resistivity.
Because these metals strongly resist the current flow, heat builds up
quickly. Low resistivity metals such as copper, brass and aluminum take
longer to heat. Resistivity increases with temperature, so a very hot
piece of steel will be more receptive to induction heating than a cold
INDUCTION COIL DESIGN
It is within the
induction coil that the varying magnetic field required for induction
heating is developed through the flow of alternating current. So coil
design is one of the most important aspects of the overall system. A
well-designed coil provides the proper heating pattern for your part and
maximizes the efficiency of the induction heating power supply, while
still allowing easy insertion and removal of the part.
coils are normally made of copper tubing – an extremely good conductor
of heat and electricity – with a diameter of 1/8″ to 3/16″; larger
copper coil assemblies are made for applications such as strip metal
heating and pipe heating. Induction coils are usually cooled by
circulating water, and are most often custom-made to fit the shape and
size of the part to be heated. So coils can have single or multiple
turns; have a helical, round or square shape; or be designed as internal
(part inside coil) or external (part adjacent to coil). There is a
proportional relationship between the amount of current flow and
distance between the coil and part. Placing the part close to the coil
increases the flow of current and the amount of heat induced in the
part. This relationship is referred to as the coupling efficiency of the
Across International IHG10 Hi-Frequency Compact Induction Heater Feature
- Specially designed for welding thin metal parts, blades and melting of small quantity of metallic materials, ultra fast.
of use: just plug in the power and connect the cooling system. Our
simple instruction allows you to use the heater in 15 minutes.
- Digital output, frequency and current displays.
- Detachable foot switch for a safer operation.
- Dual automatic and manual modes.
- Optional graphite and silica crucibles available. (melting material decides crucible type, weight and size of the material decide crucible size)
- Connection port available for remote IR or laser thermodetector to measure, display and adjust your work piece’s temperature.
- Frequency is non-adjustable, it depends on the coil design (diameter of turns, numbers of turns, copper tubing diameter and total length).
- ISO 9001:2008 registered manufacturer.
- We provide sample testing and custom made coils in our New Jersey facility.
- One year warranty and lifetime US-based parts and service support.
- Demo videos
1. Heating 0.5×0.06″ (wide x thick) 750 nickel alloy
2. Heating 2mm OD steel nail
- Overvoltage protection:
machine shuts down when input voltage is over 245V. Over voltage light
will turn on and buzzer will sound continuously. Alarm and light shut
off automatically when voltage goes below 245V.
- Overheat protection: if sensor detects heat radiator temperature is over
55°C, machine will shut down, overheat light will turn on and buzzer
will sound continuously. Increase water pressure or lower water
temperature until alarm goes off itself.
- Overcurrent/malfunction protections: machine will shut down, indicator light turned on and buzzer sounds continuously if one of these situations occurs:
- One of the machine parts becomes overheated
- Interfering signal detected
- Short circuit between workpieces and induction coils
- Machine malfunctions
- Induction coils touching each other
- Input voltage is too low
- Low water pressure protection:
if water pressure goes below 29 PSI, machine will shut down, water
protection light will turn on and buzzer will sound continuously.
wear protection gears and goggles when operating the machine. Crucibles
must be covered all the time during operation. Across International is
not responsible for any damage caused by misuse.
- Do not run no-load operation for a long period of time, it might cause damage to the machine.
- Circulating water must be pure, clean and below 45°C.
- Machine must be grounded properly all the time during operation.
- Do NOT use single-turn coil if coil diameter is smaller than 4 inches, it will cause high frequency damage to the machine.
- Thread tape (or related material) is absolutely prohibited during installation of induction coils.