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Engr. Rodnel O. Tamayo
Project Leader
ESTABLISHMENT OF INDUCTION HEATING
DESIGN AND DEVELOPMENT FACILITY
PCIEERD TP PRESENTATION
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• Heat metal parts without physical contact..
• At speeds unheard of with conventional methods..
• With pinpoint accuracy and consistency..
•
Up to 90% efficiency..• Without open flames, loud noise or harmful fumes..
• Even in special environment (submerged in liquid, inert or reducing atmosphere orvacuum)
INTRODUCTION TO IHT PROJECT
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• Bond, harden or soften metals or other conductive
materials;
• Understood and applied to manufacturing since 1920s;
• Fast, reliable process to harden metal engine parts
during WW2;
• Focus on lean manufacturing techniques and improved
quality control led to rediscovery of inductiontechnology, along with the development of precisely
controlled, all solid state induction power supplies
FACTS ABOUT INDUCTION HEATING
Aluminum brazing
Cap sealing
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Hard brazing
Heat treatmentTool brazing
Tin soldering Warm forming
Case hardening
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• Joule effect; heat with electrical current
• Hysteresis; electrical resistance of
magnetic materials resulting to internalfriction and heat
•
Material to be heated is isolated from thepower supply;
• Submerged in liquid, covered by isolated
substances, in gaseous atmosphere,
vacuum;
HOW INDUCTION HEATING WORKS
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RADIATION HEATING
Resistance heating
• Heat and melts metals,welding, brazing and
selective surface heat
treatment
• Very localized and works fast
• Very poor temp control
• Significant temp differences
across heating zone
ALTERNATIVE SOURCES OF HEAT
CONDUCTIVE HEATING
Flame heating
• Brazing, soldering,hardening, hot forming, pre-
heating for welding, etc
• Gases and fumes
• Accuracy and consistency
issues
CONVECTION HEATING
Ovens and furnaces
• Pre-heating, annealing;brazing, heat treating,
sintering
• Space requirement
• Continuous operation
• Whole part heating
•
Loss of heat into the factory
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• Produces the varying magnetic field needed
for induction heating
•
One of the most important aspects of theoverall induction heating machine
• Provides the proper heating pattern for
the part
•
Maximizes efficiency of the inductionheating power supply
• Allows easy insertion and removal of part
• Part and application specific; mass productionto justify investment
Coupling Efficiency
• Lower distance between the part – higher power
• Coupling efficiency vs part handling
Magnetic Flux Placement
• Maximum number of flux lines to the target area
• Prevent cancellation of magnetic field
• Use of flux diverters
Basic construction
• Made of copper tubing – very good conductor of
heat and electricity
• Cooled by circulating water
THE INDUCTOR
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INDUCTION HEATING DESIGN AND DEVELOPMENT
SOUTIONSREQUIREMENTS
• Inductor design
• Part handling design
•Quenching design
• Power supply selection
• Atmosphere selection
• Monitoring and control system design
• …
• Part shape and
dimensions
•
Heating result• Production speed
• Cost efficiency
• Budget
• …
CONSIDERATIONS
• Electromagnetic, thermal, metallurgical,
chemical composition, microstructure, …
• Electrical, mechanical, electronics and
controls, …
• Power supply characteristics
•…
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• Thermal, metallurgical
• Chemical
DESIGNING A CONVENTIONAL HEAT TREATMENT SYSTEM
• Part shapes and dimensions
• Heating result
• Production speed
• Equipment selection
• Part handling selection
• Power control
REQUIREMENTS SOLUTIONS CONSIDERATIONS
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DESIGNING THE INDUCTOR COIL
Basic Steps Traditional Method Software Based Method
Design and build the inductor coil; Built on large empirical data,
experiences and “rules of the
thumb”;
Years of experiences and
proprietary data ;
Numerical simulation tools to
simulate and analyse effects of
design inputs;
Cost effective and fast
development
Run trials and conduct
metallographic analysis on the
parts;
Same Same
Modification of the inductor coildepending on the results of the
analysis;
Modification based onmetallographic analysis only;
More information as bases for themodifications
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PROJECT OVERVIEW
Project Title
Establishment of Induction Heat Treatment Facility
Nickname
IHT Project
Project Leader
Rodnel O. Tamayo
Duration
2 years
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RATIONALE
Year Automotive Related Export Automotive Related Import
Estimated Qty (kg) Estimated Amt (Php)
2006 1,285,280 128,528,000 24,540,100 2,454,010,000
2007 8.090.105 809,010,500 19,436,900 1,943,690,000
2008 3,171,840 317,184,000 42,109,400 4,210,940,000
2009 778,895 77,889,500 22,777,500 2,277,750,000
2010 140,725 14,072,500 72,901,400 7,290,140,000
2011 1,246,315 124,631,500 19,530,700 1,953,070,000
2012 5,402,410 540,241,000 63,722,400 6,372,240,000
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OBJECTIVES AND DELIVERABLES
General Objectives
To establish an induction heat treatment design and development facility in MIRDC
Specific Objectives
To establish a facility that can design, simulate, fabricate and validate induction coil systems;
To design, fabricate and validate performance of at least 5 inductor coil
To design and fabricate an induction coil with the following characteristics
Capable of achieving the target case hardness – depth and profile on a component
Optimized for the existing power supply systems
Validated to meet the required heating pattern and metallurgical quality
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EXPECTED OUTCOMES
Contribute to the competitiveness and sustainability of the metals and engineering sector
Develop capability in design, manufacture and validation of induction heating system
Enable access of machine and machine parts manufacturers to induction heating systems
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BUDGETARY REQUIREMENTS
Expense Class Year 1 Year 2
PS 1,218,096 1,218,096
MOOE 2,680,000 4,130,000CO 14,045,804 0
TOTAL 17,943,900 5,348,096
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TIMELINES
Objectives and Activities Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8
Identification and acquisition of hardware, software, hire
personnel, ready utilities and location for the facility
Set up the equipment
Train key personnel in the design and simulation and analysis of
inductor systems
Identification of components to be heat treated; Identification of
the required hardness profile
Design, simulation, analysis, fabrication of inductor system for theidentified component
Validation of the performance of the inductor system by testing
and analysis of the hardness profile generated
Promotion of the facility to potential customers in the industry
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