Technologies Archives - Page 27 of 36 - induction heating machine manufacturer

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

Induction Soldering Stainless Steel To Wire

Induction Soldering Stainless Steel To Wire With IGBT High Frequency Heating Units

Objective Heat Stainless steel connector for soldering application in automotive wire harness manufacturing
Material Stainless steel connector 1.57” (40mm) long, 0.6” (15mm) OD & 0.4” (10mm) thick. Lead free solder
Temperature 392 ºF (200 ºC)
Frequency 352 kHz
Equipment • DW-UHF-6kW induction heating system, equipped with a remote workhead containing one 1 μF capacitor.
• An induction heating coil designed and developed specifically for this application.
Process A two turn channel coil is used for soldering the connector to the wire harness. The stainless steel connector and wire harness are placed in the coil for 20 seconds for the solder to
fill just the top of the connector.
Results/Benefits Induction heating provides:
• By precisely heating the metal, the plastic shroud is not directly heated
• Reduced production cost
• Faster process time, reduced production cost
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating

Induction Soldering Brass To Copper

Induction Soldering Brass To Copper With IGBT High Frequency Heating Equipment

Objective To heat brass and copper for soldering application on medical equipment
Material Brass ring, brass and copper pieces 5.11” (130mm) long, 4.3” (110mm) OD & 0.3” (7mm) at thickest point and solder rings
Temperature 392 ºF (200 ºC)
Frequency 306 kHz
Equipment • DW-UHF-10 kW induction heating system, equipped with a remote workhead containing two 0.33μF capacitors for a total of 0.66μF
• An induction heating coil designed and developed specifically for this application.
Process This process is completed in two steps that use a 3 turn helical coil. The first process is to solder the brass ring to the copper piece which takes 85 seconds. The second step is to solder a large brass piece to the first assembly. This process takes 50 seconds for a total process time of two minutes 15 seconds.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing
• Even distribution of heating
• Faster process time, current process takes 5 minutes
• Consistency by using solder rings

Induction Soldering Circuit Board

Induction Soldering Circuit Board With IGBT heating system

Objective To heat post, lead or lead-free solder preforms for various circuit board soldering applications.
Material Upper and lower circuit boards, small and large lead or lead free preforms.
Temperature < 700 ºF (371ºC) depending on the preform used
Frequency Three turn coil 364 kHz
Small two turn coil 400 kHz
Large two turn coil 350 kHz
Equipment • DW-UHF-4.5 kW induction heating system, equipped with a remote workhead containing two 0.66μF capacitors for a total of 1.32 μF
• An induction heating coil, designed and developed specifically for this application.
Process Three individual coils are used to heat the various locations on the circuit board depending upon if the location is a single application or a group application. The time varies from 1.8 to 7.5 seconds depending upon location. In production the heat stations and coils are moved into position over the post for automation purposes. Either lead or lead free solder preforms are used. The process time on the lead free solder is slightly longer.
Results/Benefits Induction heating provides:
• Hands-free heating that involves no operator skill for manufacturing, lends itself well to automation.
• Solder controlled by preforms, no excess left on board.
• Good solder flow without over heating the board and damaging adjacent circuits and components.

Induction Soldering Brass Heating Exchanger

Induction Soldering Brass Heating Exchanger Of a Series Copper Pipe

Objective To solder a brass end cap to a series of copper tubes
Material Preassembled heat exchanger with copper tubes and 2 brass end caps 2.36” (60mm) OD, 0.08” to 0.12” (2 to 3mm) thick at both ends, liquid solder
Temperature 302ºF (150ºC)
482ºF (250ºC)
Frequency 237kHz
Equipment • DW-UHF-20kW 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 dual four turn pancake coil is used to solder 2 brass caps per cycle. Liquid solder is squirted onto the end cap and is heated for 18 seconds at 302ºF (150ºC) to burn off the flux. Then the
heat is increased to 482ºF (250ºC) for 15 seconds to solder the parts.
Results
Induction heating provides:
• Even distribution of heating
• Compared to hot plate, induction heating is able to heat two parts in 30 seconds vs. one part in 60 seconds
• Increased production
• No discoloration with the slow heating process

Induction Soldering Wires Onto Connection

Induction Soldering Wires Onto Connection With IGBT Induction Heating Units

Objective Heat connector assemblies for soldering
Material Device assembly
Tin plated brass terminals Solder paste
Temperature 500°F (260°C) 5-7 seconds
Frequency 360 kHz
Equipment DW-UHF-6kW induction heating system equipped with a remote heat station, containing two 0.66 μF capacitor. An induction heating coil designed and developed specifically for this application.
Process A single turn helical coil is used to heat the solder paste. The connectors are placed inside the induction heating coil and RF power is applied for 5-7 seconds until the connector heats.
Solder paste is applied to the joint in two ways, stick-fed or manually.
Results/Benefits • Compared to using a manual soldering iron, induction heating precisely applies heat to for higher quality solder joints
• This is ideal for integrating with an automated system. By stick- feeding the solder more aesthetically pleasing parts are produced.

Induction Soldering Wire of Co-axial

Induction Soldering Wire of Co-axial With High Frequency Heating Units

Objective To solder center-conductor and shielding braid of wire assemblies to 500 (250) °F(°C).
Material • Customer-supplied assemblies
• Temperature indicating paint
• Flux-cored solder wire
Temperature 500 (250) °F (°C)
Frequency 272 kHz
Equipment DW-UHF-4.5kW induction heating system, equipped with a remote heat station containing two 0.33 μF capacitors. An induction heating coil designed and developed specifically for this application.
Process A multi-turn helical coil is used and temperature-indicating paint is applied to the joint area. The wire assembly is placed over the induction heating coil, and RF power is applied. The time-to-temperature and the heating pattern on the part are established. The next wire assembly is placed on the coil, the assembly is heated and solder wire is fed into the joint. The assembly heats well and reaches 500 °F in 10 seconds.
Results/Benefits • elimination of a crimp process
• more reliable connections are made
• faster process times

Induction Soldering Copper Tap

Induction Soldering Copper Tap on a Speaker Ring with IGBT Induction Heater

Objective Heat copper tab until the solder reflows.
Material Copper tab 0.25 X 0.25 inch square about 0.05 inches thick. Lead free solder material (higher melting temperature than regular solder.)
Temperature 500 ºF for 1.25 seconds
Frequency 286 kHz
Equipment DW-UHF-4.5 kW, 150-400 kHz solid state induction heating system equipped with a remote heat station containing one 1.2 μF capacitor and a specially-designed work coil..
A multi-turn helical coil about 3/16 inch internal diameter made out of 1/16 inch diameter tubing.
Process Solder wire is fed onto speaker tab area using an automatic wire feeder. It is then heated to re-flow the solder.
Results/Benefits With an efficient coil design induction heating easily reaches the desired reflow temperature in a very short amount of time.

Induction Soldering Stainless Steel Tubing

Induction Soldering Stainless Steel Tubing with IGBT Soldering Heating Units

Objective Heat a.125” (3.175mm) diameter stainless steel tube to a 1” diameter cylinder 1” (25.4mm) tall for a soldering application
Material Stainless steel cylinder and tube
Temperature indicating paint
Lead free solder preform rings
Temperature 300-400 ºF (150-205 ºC)
Frequency 235 kHz
Equipment DW-UHF-4.5 kW, 150-400 kHz induction power supply, equipped with a remote heat station containing two 0.66 μF capacitors (total 1.32 μF).
A three-turn pancake coil induction heating coil designed and developed specifically for this application.
Process Initial tests without solder ensured that the metal reaches the required temperature and the heating pattern on the part.Solder preform rings are placed onto the tube at the joint. The part is placed inside the induction-heating coil heated until the solder melts.
Results/Benefits Programmable and adjustable heating ramp rates achieve the desired heat profile. Too fast a heat profile does not conduct the heat through the joint and too slow a heat cycle vaporizes
or dries the flux causing poor solder flow.