Hardening Inductor Customized

Induction heat treatment is a surface heat treatment technology that uses the principle of electromagnetic induction to quickly heat metal workpieces. Its core component is the inductor (also known as the induction coil). The inductor generates a high-frequency magnetic field through alternating current, which causes eddy currents on the surface of the workpiece and quickly heats up, ultimately achieving process goals such as quenching, tempering, and annealing.

Send Email Get Best Price

Details

1. Overview

2. Structure and composition of the inductor

The inductor is usually composed of the following core parts:

1) Conductive coil:

Material: high-purity copper (good conductivity and high temperature resistance).

Shape: customized according to the shape of the workpiece, common shapes include circular rings, rectangles, spirals, U-shaped, flat plates, etc.

2) Cooling system:

Built-in water cooling pipes to prevent the coil from being damaged by overheating of high-frequency current.

3) Magnetizer (optional):

Made of ferrite or silicon steel sheets, used to enhance the concentration of the magnetic field and improve heating efficiency.

4) Insulation layer:

The surface of the coil is coated with high temperature resistant insulation material (such as ceramic, Teflon) to prevent short circuit.

3. Classification of sensors

According to the application scenario and heating method, sensors can be divided into the following categories:

Type	Specificities	Application Scenario
Scanning Inductor	Relative movement of workpiece and coil for continuous and uniform heating	Quenching of linear workpieces such as long shafts and guide rails
Simultaneous Heating Inductor	No movement of the workpiece and coil or only rotation of the part	Suitable for localized heating of step shafts and parts
Multi-turn Coil Type	Multi-turn coils to enhance the magnetic field strength, suitable for deep heating	Heat transmission of large forgings or thick-walled parts
Affine inductor	The coil shape matches the contour of the workpiece perfectly, resulting in high heating precision.	Complex geometry workpieces (e.g. camshafts)

4. Key elements of sensor design
1) Frequency and power matching:
Frequency and power determine the conductor size, wall thickness, etc. of the sensor.

2) Geometric shape optimization:

The geometric size and shape of the part determine the shape and size of the sensor.

The gap between the coil and the workpiece needs to be precisely controlled. Too large will reduce efficiency, and too small will easily cause short circuit. The frequency also affects the gap between the sensor and the part.

3) Cooling efficiency:

The water cooling flow and pressure must meet the heat dissipation requirements to avoid overheating and deformation of the coil.

5.Typical application cases

1) Step shaft quenching:

Use a contoured sensor to ensure uniform heating of each diameter.

2) Continuous quenching of shaft parts:

The scanning sensor is combined with a rotating mechanism to achieve uniform hardening over the entire length.

6. Precautions for use and maintenance

1) Operation safety:

Avoid powering on without load to prevent coil overheating or equipment damage.

2) Regular inspection:

Check whether the cooling water circuit is blocked and whether the insulation layer is damaged.

3) Troubleshooting:

Uneven heating may be caused by coil deformation or aging of the magnetic conductor.

Conclusion:

As the core component of induction heat treatment, the design and manufacturing technology of the inductor directly affect the process effect. With the development of industrial intelligence, the inductor will continue to evolve in the direction of high efficiency, precision and durability, providing stronger support for high-end manufacturing.