8 Factors to Consider when Choosing an Induction Heating ...

Induction heating systems are not as complicated as one might think, and they are incredibly versatile. To get the most out of the system, it's critical to choose the right system for your application and requirements. Here are eight factors to consider when purchasing an induction heating system for your home.

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1. Resistivity

Highly resistive metals such as steel absorb less heat, while metals with lower resistivity such as copper require more heat. Induction will heat the material directly, while non-conductive materials must be heated with a conductive base. Hysteresis will allow magnetic materials to be heated efficiently compared to non-magnetic materials, so non-magnetic materials require more power. This is why the material of the part must be considered and the conductor purchased accordingly.

2. Heating Penetration Depth

Induced currents are strongest at the surface of the part. In fact, more than 80% of the heat generated by a part is generated in the "skin" or surface. Therefore, larger parts and parts that require penetration heating require more time to heat than those that are thin or small.

3. Operating Frequency

Lower frequency, higher power systems are usually suitable for heating larger parts that need to be heated through. Lower power, higher frequency systems are usually the right choice for surface heating. In general, the higher the frequency, the more shallow the heating of the part.

4. Application Power

The output power of the induction heating power supply determines the relative speed at which the part is heated. Consideration needs to be given to the mass of the part, the temperature increase, and the heat loss due to convection and conduction. Often, the induction equipment manufacturer can help you with this assessment.

5. Need for Heat Rise

Induction produces significant temperature changes, but generally more power is required to accommodate the significant temperature changes, which will affect your power supply selection. The rate of temperature change will also affect your power supply selection. The faster the rate of change, the greater the power requirement.

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6. Coil Design

Your typical coil is made of copper and is usually water-cooled. It is important to point out the ideal coil to match the shape of the part and to consider the process. It will provide the correct heating pattern in an efficient manner, while a poorly made coil will provide slower heating and incorrect heating patterns. There are flexible coils on the market that work well with unique part geometries. An optimized coil design will maximize the efficiency of your induction power supply.

7. Climate

This is one of the obvious issues, but worth mentioning. High power thermal induction may not be required in hotter climates. Likewise, low power induction systems in cold climates may become useless. Consider your usage and how much heat you need to provide. Homes tend to use much less heat than activities such as welding, but this may vary depending on the size of your home.

8. Your Facility

Induction requires a chiller or cooling system for cooling. Low-power systems typically require compact water-to-air heat exchangers, while high-power systems may require larger water-to-water heat exchangers or chillers. In addition, you will need to allow space for the induction heating power supply and table.

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How does induction heating work?

An induction heating system includes an induction power supply which converts line power to a higher frequency alternating current. This energy is delivered to a workhead to create an electromagnetic field within the attached coil. A work piece is placed in the coil where this field induces a current in the work piece, which generates heat in the work piece. 

Induction heating is used very effectively in many processes like brazing, soldering and shrink fitting, from something as small as a hypodermic needle to a large wheel on a military tank. Many companies in the automotive industry, medical device industry and aeronautics make efficient use of induction heating in their processes. 

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