Technologies Archives - Page 26 of 36 - induction heating machine manufacturer

Induction Shrink Fitting Steel Tube

Induction Shrink Fitting Steel Tube With IGBT Heating Units

Objective Heating a steel tube to 500-1000°F for a shrink-fitting application. Determine expansion (growth) of ID at varying temperatures.
Material Steel tubes 7” OD x 4.75” ID x 5” heat zone
Type ‘K’ thermocouple to measure temperature
Thermal blanket
Temperature 500, 800, 1000 °F (260, 427, 538° C)
Frequency 66 kHz
Equipment DW-HF-7.5, 7.5 kW, 150-400 kHz induction power supply, equipped with a remote heat station containing two 1.5 μF capacitors (for a total of 0.75 μF)
A multi-turn, special series-parallel induction heating coil designed and developed specifically for this application.
Process Initial tests were completed on a sample without a thermal blanket. A thermocouple is slipped between the copper ring and the steel tube to measure temperature. The part measured
4.940” (at room temperature with an ID gauge.) The part reaches 1000°F (538°C) in about 10 minutes.
The chart below shows the comparison between theoretical and experimental measured results

Results/Benefits The part measures 4.975” at 1000°F yielding an expansion of 0.035” (4.975 minus 4.94). At 500 and 800°F the expansion numbers were 4.950 and 4.964 respectively. When using a
thermal blanket the heat time is reduced by about 90 seconds (8.5 minutes as opposed to 10 minutes).

Induction Heating Plastic Catheter Tube

Induction Heating Plastic Catheter Tube With IGBT High Frequency Heating Units

Objective Heat a metal braid in a plastic catheter tube to 250°F (121.1ºC) so that another catheter tube can be bonded to it.
Material 0.05” (1.27mm)diameter catheter tubes, some with a metal braid, ceramic rod
Temperature 250°F(121.1ºC)
Frequency 306kHz
Equipment • DW-UHF-4.5kW induction heating system equipped with a remote workhead with one 1.2 μF capacitor
• An induction heating coil designed and developed specifically for this application.
Process A single turn helical coil is used to heat the metal braid for plastic reflow. To maintain the correct inside diameter of the tubing. A ceramic rod is inserted through the tubing. Heat is applied for 3.5 seconds to reach 250°F (121.1ºC). The metal braid melts the plastic and creates a bond.
Results/Benefits Induction heating provides:
• Controlled rapid application of heat
• Consistent, repeatable results
• Energy efficient

Induction Heating Molding Catheter Tip

Induction Heating Molding Catheter Tip With IGBT High Frequency Heating Units

Objective Heat a water-cooled steel mandrel to 700°F (371ºC) to form a high quality Teflon catheter tip.
Material Teflon catheter tubing, mandrel assembly
Temperature 600-700°F (315-371ºC)
Frequency 376 kHz
Equipment • DW-UHF-6 kW induction heating system, equipped with a remote workhead containing one 0.66μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A two turn coil is used to heat the steel mandrel to 660ºF (371ºC) in 2.7 seconds. To form the catheter tip, RF power is applied while the catheter is held over the mandrel. The tubing is then pushed on to the mandrel to form a consistent, even tip.
Results/Benefits Induction heating provides:
• Precise, repeatable application of heat
• Non-contact heating
• Faster cycle times

Induction Heating Aluminum Catheter Tipping

Induction Heating Aluminum Catheter Tipping With IGBT Heating Units

Objective: To heat an aluminum catheter tipping die to above 2850F within 2 to 5 seconds for the forming of catheter material. Presently, heating is performed in 15 seconds with older induction equipment. The customer would like to use solid state induction equipment to reduce the heating times and develop a more efficient process.
Material: Aluminum catheter tipping die measuring 3/8″ OD and 2″ long with a nonmagnetic sleeve over the heat zone. The catheter material was described as being similar to polyurethane plastic. Also, a 0.035″ diameter steel wire was inserted into the catheter tube to prevent collapsing.
Temperature: 5000F
Application: The DW-UHF-4.5kW solid state induction power supply was determined to most efficiently produce the following results:
A heating time of 3.3 seconds to reach 5000F and form the catheter was achieved through the use of a two (2) over two (2) turn helical coil.
A quality catheter was formed by pressing 1/2″ of the polyurethane tube into the mold while retaining shape through the use of a 0.035″ wire to prevent collapsing of the tube.
Laboratory results show that a substantial time decrease was accomplished which will allow for a significant increase in production while not sacrificing quality.
Equipment: DW-UHF-4.5kW solid state induction power supply including a remote heat station containing one (1) capacitor totalling 1.2 μF.
Frequency: 287 kHz

Induction Soldering Fuse Caps

Induction Soldering Fuse Caps With IGBT Induction Heating Units

Objective Soldering three fuse caps simultaneously to reflow lead free solder and make a joint between the fuse cap and fuse wire guide
Material Plated copper end caps 0.375” (9.5mm) OD x 0.375” (9.5mm) height, ceramic fuse tube 1.5” tall (38.1mm) , lead free solder preforms
Temperature 700 ºF (371 ºC)
Frequency 286 kHz
Equipment • DW-UHF-20 kW induction heating system, equipped with a remote workhead containing two 1.0μF capacitors for a total of 0.5μF
• An induction heating coil designed and developed specifically for this application.
Process A three position two turn helical coil is used to solder three fuse caps simultaneously. The fuse assemblies are placed in the coil and the heat is applied in three cycles at 3.5 seconds per cycle to reflow the solder. On the production line the bottom caps are soldered first. The fuses are filled with sand and without flipping the assembly the top cap is soldered.
Results/Benefits Induction heating provides:
• Consistent, repeatable results
• Precise & accurate heat application
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Induction Soldering Brass Connector

Induction Soldering Brass Connector In Solar Panel With IGBT Induction Heater

Objective Solder three brass connectors one at a time in a solar panel junction box without affecting the components in the junction box
Material Solar panel junction box, brass connectors, solder wire
Temperature 700 ºF (371 ºC)
Frequency 344 kHz
Equipment • DW-UHF-6 kW induction heating system, equipped with a remote workhead containing one 1.0 μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A three turn oval shaped helical coil is used to heat the connectors. A piece of solder wire is placed onto the joint area and each joint is heated separately for 5 seconds to solder the connector. The total process time is 15 seconds for the three joints.
Results/Benefits Induction heating provides:
• Pinpoint accuracy deliver heating only to joint; does not affect surrounding components
• Localized heat produces neat and clean joints
• Produces high quality, repeatable results
• Even distribution of heating

Induction Soldering Steel Cover

Induction Soldering Steel Cover With High Frequency Heating Units

Objective Soldering a nickel plated steel cover onto a nickel plated steel EMI filter housing without damaging the RF circuit
Material 2” x 2” (50.8mm) nickel plated steel cover, 2” x 2” (50.8mm) nickel plated steel box and lead-free solder and flux
Temperature 573 ºF (300 ºC)
Frequency 229 kHz
Equipment • DW-UHF-3 kW induction heating system, equipped with a remote workhead containing two 1.2μF capacitors for a total of 2.4μF
• An induction heating coil designed and developed specifically for this application.
Process A single turn square helical coil is used to solder the cover to the filter box. Solder flux is applied to the filter box and two solder turns (preforms) are placed covering the perimeter of the cover. The assembly is positioned under the coil and power is applied for 7 seconds to solder the seam.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Repeatable, non-contact clean heating
• Fast precise heating
• Good solder flow without over heating the box and damaging RF circuits.
• Even distribution of heating

RF Soldering Circuit Board

Induction RF Soldering Circuit Board With High Frequency Soldering Heater

Objective Heat a circuit board assembly to 600ºF (315.5ºC) to solder RF connectors to a radar manifold.
Material Kovar connectors 0.100” (2.54mm) wide x 0.200” (5.08mm) long, circuit board and solder paste
Temperature 600ºF (315.5ºC)
Frequency 271 kHz
Equipment • DW-UHF-2 kW induction heating system, equipped with a remote workhead containing one 1.2μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A two turn helical coil is used to heat the assembly. Solder paste is applied to the joint area, the connectors are placed in the proper location and heat is applied for 10 seconds, creating
the solder paste to flow.
Results/Benefits Induction heating provides:
• Creates liquid and gas-tight joint quickly and efficiently
• Precise application of heat without affecting others areas of board
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Induction Soldering Copper Wires

Induction Soldering Copper Wires With IGBT High Frequency Heating Units

Objective Soldering two copper wires to pre-installed turrets on a copper buss bar
Material Solder dipped copper/nickel buss bar, 2 tinned stranded copper wires, brazing stick
Temperature 446 ºF (230 ºC)
Frequency 230 kHz
Equipment • DW-UHF-6kW induction heating system, equipped with a remote workhead containing one 1.2μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A four turn split helical coil is used to solder the buss bar assembly. The 2 copper wires are applied to the turrets and power is applied for 30 seconds. The brazing stick is fed by hand to the heated parts and the braze flows evenly, creating the joint.
Results/Benefits Induction heating provides:
• Reduced solder time
• Even distribution of heating
• Joint to joint consistency

Induction Soldering Aluminum Housing

Induction Soldering Aluminum Housing With IGBT High Frequency Soldering Units

Objective Heat an aluminum spotlight housing to solder an LED assembly to the inside base
Material LED housing with copper plug, aluminum spotlight housing 5” (127mm) dia at top, 1.25” (31.75mm) dia at base, temperature sensing paint
Temperature 500 ºF (260 ºC)
Frequency 45 kHz
Equipment • DW-UHF-45kW induction heating system, equipped with a remote workhead containing one 1.0μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A multi turn pancake coil is used to heat the bottom of the aluminum spotlight housing. The LED housing was not available so this application is done with temperature sensing paint to determine the feasibility. The temperature sensing paint is applied where the LED housing sits in the center of the
spotlight housing. The base of the housing reaches 500 ºF (260 ºC) in 30 seconds.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Faster production times, more energy efficient
• Consistent, repeatable results
• Even distribution of heating