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The application and development of induction heating technology at home and abroad

Induction heating has gained real application as an emerging discipline in the last 30 years. In today’s energy shortage, its importance is particularly prominent, and the technology is rapidly improving and becoming increasingly versatile. China began to develop induction heating technology after the reform and opening up, and its application prospects are very promising.

20211028230942 65194 - The application and development of induction heating technology at home and abroad

Characteristics of induction heating

  • (1) High heating temperature, and non-contact heating.
  • (2) High heating efficiency.
  • (3) Fast heating speed.
  • (4) The temperature is easy to control.
  • (5) Can be partially heated.
  • (6) Easy to realize automatic control.
  • (7) Good operating environment, almost no noise and dust.
  • (8) Small working area and high production efficiency.
  • (9) Can heat the workpiece with complex shape.
  • (10) The workpiece is easily heated evenly and the product quality is good.
  • (11) The solution in melting has electromagnetic stirring effect. Can evenly adjust the composition of the metal liquid, the solution temperature is uniform, there is no local high temperature. Metal burn less, which is more important for melting rare metals.

Advantages of induction heating

First of all, low energy consumption. Induction melting furnace and induction heat transfer furnace of the actual billet heating thermal efficiency can reach 65% to 75%, while the flame furnace and a variety of chamber furnace is only about 30%.
Second, this type of furnace without coal furnace, gas furnace and resistance furnace and other necessary preheating process, easy to use, simple operation, can work continuously for a long time can also be turned on or stop working at any time as needed, fully manual or fully automatic or semi-automatic work, that is, in production scheduling with absolute advantages.
Third, no need to heat the workpiece as a whole, can choose local heating, so less power consumption, small deformation of the workpiece and fast heating speed, can make the workpiece in a very short time to reach the required temperature, so that the workpiece surface oxidation and decarburization and other heating defects to a very low degree, can be used for steel, tungsten, molybdenum and other steel materials can also be applied to the chemical activity of strong aluminum, titanium, zirconium, niobium heating or heat treatment.
Fourth, induction heating equipment can be installed in the production line, easy to realize the automation and mechanization of the production line, easy to manage, can effectively reduce transportation, save manpower and improve production efficiency.
Fifth, induction heating also has the advantages of high utilization of electrical energy, environmental protection and energy saving, safety and reliability and good operating environment.
Based on the above advantages, in the electric energy instead of coal, oil, gas and other non-renewable energy in the heating field is gradually becoming the dominant energy today, induction heating in melting, heating and other fields are increasingly widely used, electric heating, especially the application of induction heating has a very wide application prospects, induction heating equipment manufacturers have a broad space for development.

Application in automobile manufacturing

The booming development of the automobile industry has brought unprecedented development opportunities to the auto parts industry. Induction heating technology in the field of automotive manufacturing is also being more and more widely used.
In melting, casting is an easy-to-form metal processing method. The casting method can be used to make a variety of different sizes and complex shapes of parts for automobiles. It can be said that in the development of the automotive industry, almost all the casting process methods in the automotive industry can do its best. The production of domestic and foreign casting automotive parts are mainly used in the melting process cupola melting process, medium frequency induction furnace melting process and cupola – medium frequency induction furnace duplex melting process, and induction melting furnace due to its technical advantages in the foundry industry is also being increasingly widely used.
In heating, according to statistics, the former Soviet Union in the automotive industry induction heat treatment of parts has accounted for 40% to 45% of heat treatment parts. Induction heating technology has developed to today, its application and the degree of development speaks for itself.
Induction heating technology in the automotive industry is mainly used in the following areas.

  • (1) The melting of metals.
  • (2) Heating of forging blanks.
  • (3) Heat treatment of automotive parts.
  • (4) Induction heating curing of automotive parts after bonding.
  • (5) Induction heating semi-solid forming.
  • (6) Induction heating assembly.
  • (7) Induction heating brazing.

Status of foreign induction heating

With the development of power semiconductor devices and power electronics technology continues to develop, the face of induction heating devices are also changing, with the volume of the device, quality, performance changes are particularly prominent. For example, frequency, the same capacity of the transistor type frequency conversion device compared with the electronic tube type frequency conversion device volume reduction 2 / 3, weight reduction 2 / 3, cooling water saving 1/2, power consumption saving 1/3, efficiency increased by 35%, longer service life, more safe and reliable, easy to achieve automatic control, conducive to improving the heating efficiency and quality, maintenance workload is smaller, can do with the use of open.
Germany, the United States, the United Kingdom, France, Japan, Italy, Spain, Belgium and Russia and other industrially developed countries in the development and application of induction heating device technology is at the forefront of the world.

Domestic development and the current situation

The application of induction heating technology in China began in the 1950s, the development is mainly after the reform and opening up, mainly for machine tools, automobiles, tractors and other manufacturing industries. Induction heating is concentrated in the workpiece surface quenching, while the application of melting and heat transmission is less. Induction heating technology almost all from the former Soviet Union and the Czech Republic. 80s, Zhejiang University independently developed the first parallel thyristor medium frequency power supply and to promote the country.
In the 1990s, some foreign induction furnace companies came directly to China to set up factories, such as the American Inductive Heating Company and Pillar Company, etc., and domestic manufacturers in the same industry compete with each other. Their products have high technical content, high power supply, full brand, large furnace tonnage, large scale production line, occupying a large part of the domestic market. Only the high price of their equipment (domestic products with the same performance is about 1/5 of its price), which makes the domestic manufacturers have a certain market development space.
Domestic induction heating from the geographical area is also divided into the “South” and “North” technology and product competition. The representative of the “Southern School” are Zhen Wu, Sida, Zhaoli and other companies; the “Northern School” is represented by induction heating companies in Xi’an, these manufacturers are more influential in Xi’an Bodai Electric Furnace Co. Electric furnace factory, Xi’an Institute of Mechanical and Electrical Research, Shaanxi Haiyi, Xi’an Automation and Huali, etc.

Development trend of induction heating device

Induction heating device consists of two parts, one is the AC power supply to provide energy, also known as frequency conversion power, the other part is to complete the induction coil and mechanical structure of electromagnetic induction energy conversion, called induction furnace. Variable frequency power supply has the industrial frequency, medium frequency and high frequency.
(1) High frequency heating equipment
It has a set of frequency 50Hz alternating current into high frequency (70 000 ~ 1000000Hz) electrical energy devices, usually using electronic tube high frequency generator.
(2) Medium frequency heating equipment
It also has a set of equipment to transform the industrial frequency 50Hz into medium frequency (500 ~ 10 000Hz) electrical energy, usually medium frequency generator (low power factor) and thyristor inverter.
(3) Industrial frequency induction heating equipment
The power frequency of the inductor is the same as the frequency of the power grid, i.e. 50Hz, so it can draw energy directly from the power grid. The shortcoming is that the power factor is too low.
With the development of market demand, the development of induction heating device presents power supply with power electronic power devices of large capacity becomes high frequency, electronic technology device control analog to digital, automatic control to intelligent development, the development trend of induction heating device presents the following aspects of the characteristics.
1) Power tends to high-frequency high-capacity
Induction heating power supply in the medium frequency band mainly using thyristor; supersonic frequency band mainly using IGBT; high frequency band was SIT, now the main development of MOSFET power. The use of IGCT power supply also began to debut. The need for high-frequency power has given rise to new power devices, and new devices in turn to promote the development of high-frequency power. Induction heating power supply of large capacity, such as tens of megawatts, hundreds of megawatts, are achievable.
2) Induction heating device tends to mechanization, automation
In recent years, with the rapid development of mechatronics, computers, information and control, equipment automation, new materials, new processes, etc., casting, forging and heat treatment process tends to digitalization, precision. Reflected in the demand for heating trends for: digital manufacturing into the casting and forging process, including heating, melting equipment; casting and forging short process production requirements to reduce resource waste; large castings and forgings production requirements for industrial energy saving; automation control under clean production.
Therefore, induction heating equipment in its energy-saving and environmentally friendly features, there should be market demand to large-scale, automation and control tend to intelligent direction of development.

Source: Network Arrangement – China Pipe Bend Manufacturer – Yaang Pipe Industry (www.epowermetals.com)

(Yaang Pipe Industry is a leading manufacturer and supplier of nickel alloy and stainless steel products, including Super Duplex Stainless Steel Flanges, Stainless Steel Flanges, Stainless Steel Pipe Fittings, Stainless Steel Pipe. Yaang products are widely used in Shipbuilding, Nuclear power, Marine engineering, Petroleum, Chemical, Mining, Sewage treatment, Natural gas and Pressure vessels and other industries.)

If you want to have more information about the article or you want to share your opinion with us, contact us at sales@epowermetals.com

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