ENRX I What is induction heating

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The induction coil, often referred to as an "inductor" or simply a "coil," is a crucial component of an induction heating system. Unfortunately, it is frequently overlooked and misinterpreted. Many individuals view the coil merely as a copper tube that allows cooling water and alternating current to pass through. However, this perception is far from accurate. A well-designed and expertly crafted coil significantly impacts several aspects of the induction heating process.

Correct Process Outcomes

The coil's physical characteristics profoundly influence the heating patterns, temperatures, and heat penetration depths during the induction heating cycle. A poorly designed or manufactured coil can lead to subpar results.

Cost Control

A professionally designed and manufactured coil, when adequately maintained, boasts a longer and more productive lifespan compared to amateur counterparts. Additionally, a correctly built and maintained coil helps reduce waste.

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Overall System Efficiency

ENRX induction heating systems are optimized to work with ENRX coils. Utilizing the appropriate coils leads to substantial long-term savings.

A Crash Course in Coils

Designing and manufacturing induction coils is a complex task. Below are three significant challenges that must be addressed to create safe, efficient coils.

Through-Flow Rate

Ensuring adequate cooling water flow through the coil is critical, especially for high-power density coils, where low flow can result in inadequate thermal transference. A booster pump may be necessary to maintain the desired flow. Skilled designers always specify a purity level for the water to minimize internal corrosion of the coil.

Magnetic Flux Concentrators

Concentrators are essential as they direct the current within the coil area that faces the workpiece. Without these concentrators, a significant amount of magnetic flux could escape around the coil and affect nearby conductive components. Concentrators are made from laminations or pure ferrites, along with ferrite- or iron-based powders, each offering different benefits and drawbacks.

• Laminations provide the highest flux densities and magnetic permeability while being more cost-effective than iron- and ferrite-based powders. However, they come in standardized sizes and can be labor-intensive to mount.
• Pure ferrites exhibit excellent magnetic permeability but suffer from low saturation flux density, making them brittle and difficult to machine.
• Iron powders are easy to shape and offer high flux densities. However, precautions must be taken against overheating, as these powders have relatively low working temperatures due to internal losses or heat transfer from the heated workpiece.

Impedance Matching

Achieving the correct impedance matching between the coil and the power source is essential to utilize the latter's full power. Designers must also account for the fact that coils require five to ten times more reactive power than active power.

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