iew Your partner for induction heating systems for manual and automated solutions 22.09.2014 1
A warm welcome from Presenters: Simon RIEFLING and Dipl.-Ing. Martin SCHWEIKHART Sales Manager Germany / Managing Director 2
Headquarters of the iew GmbH iew Induktive Erwärmungsanlagen GmbH Novomaticstraße 16 A-2345 Gumpoldskirchen International offices: Germany Spain Switzerland Sweden Finland France iew 15km south of Vienna Portugal Croatia Liechtenstein China Slovenia Bosnia-Herzegovina 3
Company history of the iew GmbH 1994 Diploma thesis of MD Martin Schweikhart at the TU Vienna High frequency Megahertz Generator for the inductive heating of metals 1996 Foundation of the engineering office Schweikhart 1997 Change of corporate form to iew Induktive Erwärmungsanlagen GmbH 2003-2007 General agency in Austria for impac in the infrared pyrometer sector for temperature measurement 2007 New business area fixture construction 2008 New headquarters in Gumpoldskirchen 4
Business areas of iew GmbH Production & Sales of medium frequency & high-frequency induction heating units Power: 2kW - 25kW Frequency: 70-450kHz Fixture construction for special devices Consulting & Solutions for customized heating tasks 5
Areas of application of induction heating Brazing & soldering Inert gas- and vacuum technology Science and material testing Annealing Shrinking Adhesive bonding Smelting Hardening and tempering General heating of metals 6
Principle of induction heating Eddy current losses within the material itself Electrical conductive material can be heated directly Eddy current losses apply to all materials Hysteresis losses for magnetic workpieces only Principle schematic of induction heating 7
Frequencies Since the current penetration depth is dependent on the operating frequency, higher or lower frequencies are generated depending on the application. The range of applicable frequencies is divided into lowfrequency / line frequency (50 to 500 Hz), medium-frequency (0.5 to 50 khz) and high frequency (50 khz to 30 MHz), wherein the penetration depth reaches >8 mm in the low frequency range and about 0.1 mm in the high frequency range. The dependency of penetration depth as a function of the frequency is described by the skin effect. 22.09.2014 Low frequency: MF: HF: e.g. Shrinking thick parts thin and small parts iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 8
Skin-Effect The skin effect is an effect in electrical conductors that are flown through with an alternating current whereas the current density inside the conductor is lower than in its outer areas. Penetration depth Equivalent conductive layer thickness δ and actual current distribution in the conductor cross-section seen in the illustration above. 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 9
Temperature measurement: Infrared pyrometers vs. Thermocouples Contact-free temperature measurement Easy adjustment to various measuring points Thermocouples need to be attached or pressed onto the measuring point Thermocouples generate an overlay voltage As a result the measurement of the actual temperature is impossible and an average temperature value must be formed Inductor with workpiece Thermocouple Infrared pyrometer 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 10
Temperature measurement: Infrared pyrometers vs. Thermocouples In the pyrometer metrology the emission factor has to be set up properly for accurate temperature measurement of the workpiece. Components with a black surface have an e-factor of 100% and reflective parts offer a lower value in the range of 30-50%. To adjust the e-factor, the pyrometer and the thermocouple are usually matched to one another. For this purpose, the two measurement points have to be adjusted to the same location of the sample, then heat the workpiece inductively to the target temperature and while turning off the inductor the e-factor can be parameterized with a digital programming point of the pyrometer (RS232 / RS485). If the sample cools down too quickly during the set-up, the process can of course be repeated and the e- factor can be fine-adjusted. 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 11
Induction vs. Chamber furnace Advantages High temperature gradient High power transfer None or very little ambient heating No sound pollution Low running costs Ready to use Disadvantages Problems with the heating of materials with high heat capacity and/or electrical conductivity Less flexible in terms of various component geometries Possible problems with the homogeneity 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 12
Inductor technology Tunnel inductor Construction drawing Infield inductor Thorn inductor Areal inductor Fork inductor Inductors can be adjusted to customer-specific requirements to realize an optimal heating zone! 13
Application: Science & material testing Heating of titanium aluminides Heating of tensile specimen Heating of tensile specimen Heating of tensile specimen Heating of gas with the help of Indirect heating of a ceramic metal balls sample 14
Completed iew projects in the area of science and material testing 15
Project ZWICK DLR Cologne: Key Facts TTH10 incl. PLC-sequence control, 3 infrared pyrometers and 1 thermocouple Heating of a ceramic sample utilizing a susceptor tube Even heat transfer of the susceptor tube to the ceramic sample Temperature control with 3 infrared pyrometers and a thermocouple for adjustment at up to 1200 C. To prevent a convective flow of heat and to further increase the homogeneity, the cabin was lined with a thermo resistant wool Used in new fiber composite ceramic developments for heat shields in the aerospace sector Due to the requirement of a very high temperature gradient, a chamber furnace could not be used 16
Project ZWICK DLR Cologne 17
Project ZWICK DLR Cologne 18
Project ZWICK DLR Cologne Video Prüfung eines Suszeptors 19
Project ZWICK Russian space agency: Key Facts TTH15 incl. PLC-sequence control and thermocouples Material testing of new metal alloys for the aerospace industry Heating of round- and tube samples Application of the Code of Practice with respect to temperature homogeneity over the sample cross-section and sample length lo Several temperature cycles (heating, holding, cooling, heating, etc.) High demands on the control accuracy during the heating and cooling phase Forced air cooling to simulate the quenching behavior of metals Temperatures of up to 1500 C, temperature gradients of 5 K/sec Type K and S themocouples 20
Project ZWICK Russian space agency 21
Project ZWICK Russian space agency 22
Project ZWICK Russian space agency 23
Project ZWICK Russian space agency Video Zugprobe 24
Project ZWICK Russian space agency 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 25
Project ZWICK Russian space agency 22.09.2014 iew Induktive Erwärmungsanlagen GmbH - AUSTRIA 26
Project ZWICK Russian space agency 27
Project ZWICK Russian space agency 28
Project ZWICK Russian space agency 29
Project AUDI: Key facts TTH3t incl. PLC-sequence control and 1 infrared pyrometer Investigation of adhesive joints in metallic components in the automotive industry at various heating temperatures New development of adhesive bonds 30
Project AUDI Video Prüfung einer Klebeverbindung 31
Projekt TU FREIBERG: Key facts TTH3 incl. Regulus control, 1 infrared pyrometer and Thermoelement Heating of ceramics by means of a susceptor tube at up to 1050 C 32
Project TU FREIBERG Video Indirekte Erwärmung einer Keramikprobe 33
Project DECHEMA: Key facts TTH5 incl. PLC-sequence control and 1 infrared pyrometer Halogenation of titanium aluminides for the aviation industry at around 600-700 C The halogenation prevents the diffusion of oxygen into the workpiece Approx. 150 cycles are conducted with heating, holding, cooling etc. 34
Project DECHEMA Video Indirekte Erwärmung einer Keramikprobe 35
iew references 36
Thank you for your interest and attention... iew Induktive Erwärmungsanlagen GmbH Novomaticstraße 16 A-2352 Gumpoldskirchen Tel: ++43 / (0)2252 607 000-0 Fax: ++43 / (0)2252 607 000-20 Email: office@iew.eu Homepage: www.iew.eu 37