VASMIN
Associates
Inductor design tips with
case studies
By
V.K.SOOD
Managing Partner
09871090015
Inductor Design VASMIN
Associates
The Importance of Coil Design
The size and shape of the water-cooled copper coil must follow the
shape of your work piece and the variables of your process. The correct
heat pattern maximizes the efficiency of heating.
Inductor design
It is based on Electromagnetic induction and skin effect principals of Induction
hardening
Inductor Design VASMIN
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Controller
Feedback system
AC Supply
Heat
Power
station
station
Inductor
coil
Basic Construction
Inductors are often made of copper tubing - a very good conductor of heat and
electricity - with a diameter of 1/8" to 3/16"; They are made of copper square or
pipes. Inductors 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 inductors can
have single or multiple turns; have a helical, round or square shape; or be
designed as internal (part inside inductor) or external (part adjacent to inductor).
Current density of coil
Current carrying capacity of copper is 13 Amperes per mm square
Inductor Design VASMIN
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Coil current
Example 50 KW Power source
Primary no of Turns N1 , Primary Current I1
Secondary no of Turns N2 , Secondary current I2
I1xN1=I2xN2
and if N2 becomes 1 no then I2 becomes very high (around 2000 A) which
passes in the coil with it’s given frequency resulting heating the part surface quickly
Power used depends on the impedance of inductor coil and part resistance (XL + R)
- The resistance of the work changes with the increase in temperature
- Thus impedance of the coil changes continuously and to maintain the coupling
there a slight change of frequency while heating .
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Inductor Design Associates
Operating Frequency
The higher the frequency, the shallower the heating in the work piece.
Depth of Penetration
Induced current in the work piece is most intense on the surface, diminishing
below the surface; 80% of the heat produced in the part is produced in the outer
'skin'.
Coupling Efficiency
There is a proportional relationship between the amount of current flow
and distance between the inductor and part. Placing the part close to the
inductor 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
inductor.
Inductor Design VASMIN
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Inductor design follows Flemings left hand rule and Faraday’s law
Induction law of Faraday
If a ‘massive’ conductor (e.g. a cylinder) is placed in the alternating magnetic field
instead of the sort circuited loop, than eddy currents (Foucault currents) will be
induced in here .
The eddy currents heat up the conductor according to the Joule effect.
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Inductor Design Associates
Direction of electromagnetic
lines passing through each
limb is opposite to each
other resulting no heating
Bad design of coil Good design of coil
As per the Flaming Left hand rule the direction of the electromagnetic field should not
be opposite to the adjacent limb of the coil so that Resultant magnetic flux generated in
the process should not reduce.
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Case studies – Inductor coil
Associates
Inductors with flux concentrators
Ferrite cores and stamping cores are used as concentrators of the
electromagnetic fluxes for the deep penetration of the heat in radius and
high depth of hardening.
Typical example of Hollow shaft Inductor using flux concentrators
Computer model of the sequential dynamics of induction scan hardening a
hollow shaft using a two-turn MIQ (machined integral quench) inductor with
an “L”-shaped flux concentrator ring (frequency = 9 kHz).
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Computer model of
the sequential
dynamics of
induction scan
hardening a hollow
shaft using a two-
turn MIQ (machined
integral quench)
inductor with
an “L”-shaped flux
concentrator ring
(frequency = 9 kHz).
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Case studies – Inductor coil
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Typical design of Series and parallel inductor coils
assemblies
Parallel Inductor coil Assy Series Inductor coil Assy
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Case studies – Inductor coil
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Special design for bore cum quench inductor coil assembly
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Case studies – Inductor coil
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Cam Shaft Hardening inductor coils
Case studies – Inductor coil VASMIN
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Inductor for surface hardening of tripods. The inductor
head is equipped with magnetic flux controllers, main
quench and screen quenches.
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Case studies – Inductor coil
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Horizontal Induction coil with built-in quench
assembly
Case studies – Inductor coil VASMIN
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Typical example of
Gear hardening with
dual frequency
power source
Multi Frequency hardening
‘Multi Frequency Concept’ (MFC) ensures simultaneous delivery of two different frequency
ranges to the same induction coil. The result is a system that always allows an optimized
heat distribution in the work piece. The exact mix of high- and medium-frequency power
delivered by MFC makes it ideal for the contour hardening of complex geometries
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Inductor design for a complex round part Associates
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Case studies – Inductor coil
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Special design for Slewing ring hardening
without soft zone
Case studies – Inductor coil VASMIN
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Special designed
crank shaft hardening
inductor coil with U
shape design easy for
positioning the
inductor on pin or
journal without
changing the setup
Inductor for a conical part VASMIN
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“YOUR GROWTH PARTNER THRU
VALUE ADDED SERVICES TO
MANUFACTURING INDUSTRIES
ASSOCIATES”
V.K.SOOD
Managing Partner
VASMIN Associates
27, Shankar market, Connaught circus
New Delhi 110 001, India
Cell no +91-9871090015 Phone +91-11-30422704
[email protected]
