Soldering Tools Surface Mount
soldering tools surface mount
Find the widest range of induction heating for forging, soldering, annealing, etc.
More Resort welder Induction Heating for Preheating, Stress
Traditional Induction heating system "> Induction heating equipment
– Soldering
– Soldering
– Surface hardening
– Start
– Bonding
– Curing
– Encapsulating
– Melting point
– Forging
– Super Heating
– Crystal Growing
Although many Industry uses induction heating for decades, it is a newcomer to industrial and construction applications with welding. Preheating before welding and stress relief (Ie, ignition) after welding the new uses for induction heating are, and companies with weldiang-intensive operations significantly increases the efficiency as a result.
Induction heating: how it works
Induction heating systems employ non-contact heating. They induce heat electromagnetically instead of a heating element in contact with a part in thermal behavior, as well as resistance heating. Induction heating acts more like a microwave, the unit remains cool, while the food cooks from within.
In an industrial example of inductive heating, the heat in the part, putting themselves at a high frequency-induced magnetic field. The magnetic field generates eddy currents in the interior of the part, the exciting part of the molecules and heat. Since the heating occurs slightly below the metal surface no heat is wasted.
Induction Heating's similarity to resistance heating is that heat is required to by the section or a part of heat. The only difference is the source of heat and the temperatures of the tool. The induction process heats the part, and in the resistance process heats the surface of the component. Depth of heating depends on the frequency. High frequency (eg 50 kHz), heat near the surface, while the low frequencies (eg 60 Hz) penetrates deeper in the partial transfer of the heat source to a depth of 3 mm, so that heating of thicker parts. The induction coil does not heat up, because the conductor for the current transported large. In other words, the coil is not too warm-up heat to the workpiece.
Induction Heating Components
Induction Heating Systems can be air-or water-cooled, depending on the application requirements. A key component for both systems is used, the induction coil to generate heat in the part.
Air-cooled system
A typical air-cooled system consists of a power source (5 kW or 25 kW), induction ceiling and connected wires. The induction Ceiling consists of an induction coil by isolation and sewn into a high temperature, removable sleeve surrounded Kevlar. This type of induction system to a controller to to monitor and automatically control temperature. A system equipped with a controller requires the use of a temperature indicator. The system could also be on a remote off switch. Air-cooled systems for applications up to 400 ° F, designated as pre-heat only system.
Liquid System
Because liquid cools more efficiently than air, this kind of induction heating system are used for applications with higher temperatures, such as high-temperature preheating and stress relieving. The principle differences are the addition of a water cooler and the use of a flexible liquid tube that houses the induction coil. Liquid Systems in general and with a temperature controller and built-in thermometer, a crucial component in stress relieving applications. The typical stress- Process requires a step to 600-800 degrees F, followed by a ramp or a controlled temperature rise to a soak temperature of about 1250 ° F. After a hold time, is the partial control to between 600-800 degrees F. The cooling temperature recorder collects data on the part of the actual temperature profile on a thermocouple input, a QA requirement for stress relieving applications. The actual procedure will be determined by the type of work and the applicable code.
Induction heating Benefits
Compared to conventional pre-heating and stress relieving methods of induction heating offers numerous advantages, including improved thermal uniformity and quality, reduced cycle times and reduced costs for consumables. Induction heating is also safe, reliable and easy to use, and scores higher than alternative technologies in energy-efficiency and versatility.
Uniformity and quality
Induction heating is not very sensitive to coil Placement or spacing. In general, the coils are uniformly distributed and centered on the weld. On systems that are so equipped, to a temperature controller to create the demand for power in an analog fashion, provides just enough power to maintain the temperature profile. The power source provides power throughout the process.
Reduced cycle time
The method of induction preheating and stress relieving offers a much faster time-to-temperature. On thicker applications, such as high pressure Steam lines can slash two hours of induction heating cycle time. It is possible to reduce cycle time of the control of temperature to soak temperature. If with other factors combine ease of use, it is not unusual that 50 percent expect a total cycle time reduction.
Lower costs for consumables
The insulation used in induction heating is easy to attach to piece work and can be reused many times. Conversely, ceramic fiber insulation can be used in resistance heating only once or twice before it is to be used will be discarded, requiring a large body of thermal insulation and high cost for the disposal of potentially hazardous material. In addition, compared to the resistance system, induction coils are robust and do not require fragile Wire or ceramic materials. Also, because the induction coil and connections do not work at high temperatures, they are not subject to degradation, such as ceramic heating pad.
Ease-of-use
A major advantage of induction preheating and stress relieving is its simplicity, ease of use contributes. Isolation and cable are easy to install, usually in less than 15 minutes. has http://inductionheater.net treatment "> boilermakers and pipefitters showed how to use the training the induction devices with just one day.
Power efficiency
The inverter power source is 92 percent efficient, a key advantage in a Era of skyrocketing energy costs. In addition, heating the implementation process more than 80 percent efficient. needs in terms of power consumption, the induction process only one row for 40 amps power 25kW.
Security
Preheating and stress relieving by the induction method is extremely employee-friendly. Induction heating requires no hot radiators and connections. Very small particulate air associated with the insulation blankets, and the insulation itself is not at temperatures about 1800 ° F, can lead to isolation, decay into dust and then breathed by workers.
Reliability
One of the most important factors for productivity in stress relief is not interrupting the cycle. In most cases this means interrupting the heat treatment cycle must be rerun be, which is significant when a thermal cycle can take a day to complete. The induction heating system components make cycle disruption unlikely. The wiring for the induction is simple, making it less likely to fail. No contactors are used to control the heat input to the part.
Versatility
The Duoline induction heat treatment system was originally developed for preheating and stress of the pipe. Well, of users of induction heating systems have adapted the process for weldolets, elbows, valves and other parts. One of the aspects of induction heating makes it the attractive to the complex forms is the ability to adjust the coils during the heating process to produce unique parts and heat sinks located. The operator can start the process, determine the influence of warming in real time and modify the coil position to change the result. Finally, the induction cable without waiting for the air cooling be moved at the end of the cycle.
Induction heating in welding applications
DUO LIN systems "> Induction Heating Systems, Co, Ltd, the manufacturer of induction heating systems for welding applications, including best has its technology to a number of projects, oil and gas pipelines, Construction equipment construction and maintenance and repair of mining machinery. Summaries of the various projects are presented below.
Oil pipeline
A North American oil pipeline maintenance work had used a combination of propane torches and electrical resistance to pipe prior to welding or encirclement repair sleeves Stopple Furniture heat the pipeline is 48-inch belt. While many repairs without stopping oil flow or drain from the pipe could be made in the presence of the crude itself welding efficiency due to the heat sink effect hinders the flowing oil. Propane torches require constant interruption of welding, to keep heat and resistance heating – during a continuous heat – often could not meet required weld temperatures.
The Company turned to maintenance induction heating as a solution. On encirclement sleeve repairs were two parallel systems are used with 25kW blankets get a preheating reduced from 125 degrees F. As a result, cycle time 8 to 12 hours to 4 hours a circumferential weld. Preheating for a Stopple fitting (a "T" intersection with valve) repair had been even more difficult by the installation of the larger wall thickness. With induction heating, but the company four 25kW systems used in parallel with a ceiling set-up. Two systems were on each side of the "T". A system was used on the main line to preheat the oil and the second was used to preheat the "T" at the circumferential weld. The preheating temperature was 125 degrees F. The weld reduced from 12 to 18 hours to seven hours a circumferential weld.
Natural Gas Pipeline
A natural gas pipeline construction project involved building a 36 inch diameter, 0.633 in. pipeline from Alberta, Canada to Chicago. On the spread of that pipeline, the contractor used welding process 25kW two power sources mounted on a tractor with the induction ceilings associated boom for speed and comfort. The power sources were used to preheat both sides of the pipe connection. Critical to this process was the speed and reliable temperature control. The increase in alloy content Materials to reduce weight and to weld, and increase in quality of life, controlling preheating is becoming critical. In this induction heating Application, it takes less than three minutes to get 250 degrees F preheat temperature, compared with about five minutes with traditional methods of heating. Beyond were temperature distribution and improved operator safety.
Heavy Equipment
A heavy equipment manufacturer often weld adapter to its Loader bucket teeth edges. Before the tack welded assembly was moved back and forth, wait for a large oven, the demand for the welding operator, until the part again was warmed up. The manufacturer decided to induction heating at the Meeting of the motion of the product Preheat trying to prevent. The material is 4 mm thick with a high Required preheating due alloy content. Duoline Electric worked with the customer tailor-made induction blankets to the specific requirements to be developed. The isolation and Coil design, provided the additional benefit of shielding the operator from the part of the radiant heat. Overall, the transactions were much more efficient and reduces welding time and maintaining temperature during welding.
Mining equipment
A mine had experienced cold cracking problems and inefficiencies with propane preheating Heaters in its repair of mining machinery. Welding operators had to remove a conventional insulating blanket out of the thick part to heat frequently and keep the part at the right temperature. The mine decided to try using induction heating, flat ceilings, air-cooled, the parts are preheated prior to welding. The induction of heat applied to the part quickly. It could also be used continuously during the welding process. Weld repair time was reduced by 50 percent. Above , the energy source was equipped with a temperature control to the part on the target temperature to hold. This virtually eliminates rework due to cold cracking. The customer reported an annual savings of $ 80,000.
Power station
A power plant builder, he was a natural gas power plant in California. Boilermakers and pipefitters been experiencing delays in construction due to the preheating and stress relieving methods that they were employed at the factory steam lines. One of the largest Problems for this contract was the reliability of the electrical resistance equipment supplied by the contactor and plug failures and broken wires on the heating pad suffered with stress relief. Extensive reworking as a result, with long heating cycles combined, was significantly delayed construction. The company brought in induction heating technology in an attempt to increase efficiency, especially for working on medium to large steam lines, as these pieces bear the heat treatment time at a construction site is required.
used on a typical 16-inch Weldolet with a 2-inch wall thickness, preheating and stress resistance to the five-and-a-half hours. Induction Heating could shave two hours off time-to-temperature (600 degrees F) and another hour to reach soak temperature (600 degrees F to 1350 ° F) to relax. The simplicity of the casing the induction blankets complex forms further reduces the time to treat lead the heat. It took the technicians 15 minutes a joint that requires two workers two hours would have to prepare a set-up to wind resistance.
Clothes Iron Surface Mount Desoldering / Bügeleisen auslöten
Welding & Soldering Tools | | July 6, 2010 | 
Comments (0)
diy, electronics, howto, pcb, soldering
