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eldec Generators CUSTOM LINE: Customized Energy Source for Perfect Induction Heating

Published 23 November 2016 | By EMAG eldec Induction GmbH

The experts at EMAG eldec have been developing generators for more than 30 years, including customized models in their CUSTOM LINE. All the resonant-circuit components are engineered in conjunction with the control architecture to form a customized product, which provides induction heating with high efficiency, controlled application of energy, and stable processes.

In order to make this process successful, close collaboration with the customer is required throughout the entire development process of the generator.

eldec Generators CUSTOM LINE

eldec CUSTOM LINE: the energy sources can be configured with single or multiple outputs and a wealth of power and frequency combinations

Versatility in Induction Hardening Technologies

Induction hardening technologies have many possible application areas. This efficient technique is used in the manufacture of plant and machinery, in the automotive sector, in aerospace, and in tool and die making.

In the latter case, it is used to harden precisely those features of the tool or die that carry the greatest load later in the punching or embossing machine. Another typical area of application is the heating of components for a subsequent joining process. The technology is also used in standardized applications like induction brazing and soldering, especially in the energy sector. Its decisive advantage here is precise targeting: The electromagnetic field applied can be adjusted perfectly to the work piece in terms of its frequency, output, and field characteristics, so only a very precisely defined area is actually heated.

eldec Generators CUSTOM LINE

The technology is also used in standardized applications like induction brazing and soldering, especially in the energy sector. Shown here: soldering of a shading ring

This precise application of energy also ensures speed, minimal work piece distortion, and economical energy consumption. Apart from the inductor, the generator attracts the special attention of the developers. The Induction specialists at eldec offer its customers not only the standardized models of the PICO, MICO, and ECO series, but also the tailored products of the CUSTOM LINE. Harry Krötz, head of Electrical Engineering R&D at eldec, explained the situation:

"We always adjust the resonant circuit, the inverter, and the inverter control to match the inductor, the required frequency, and the output. We do that even with our more standardized series, with which we can currently cover about 80 percent of applications. With our CUSTOM LINE, however, virtually all the components can be configured in a fully variable way -- from general device control to the outputs and interfaces."

eldec Generators CUSTOM LINE

Shading rings for electric motors are soldered using a medium-frequency generator with a field-guided ring inductor

Almost infinite number of possible variations

Apart from equipping their technology with single or multiple outputs, the eldec engineers distribute the output of the generator however they wish. For example, it can be made available in parallel for independent control, or it can be supplied in an "either-or" arrangement so it is only ever available at one of the outputs at a time. What are the advantages of multiple outputs for the user?

"That depends on the heating task," Krötz explained. "For example, you could use them to heat several locations on the part at the same time, speeding up the cycle time. You could also connect a variety of inductors to just one generator and operate them one after the other. This would allow you to reduce your purchasing costs for heating equipment if the cycle time was of secondary importance."

At the same time, eldec is always able to modify the power and frequency features of its devices in virtually unlimited ways to adapt the process to the customer's needs.

"More and more often customers are asking for HF generators with very low frequencies, even below the 80 kHz mark," Krötz said. "Typically, we can even satisfy those requests. eldec also offers customized generators for outputs below 20 kW. For instance, we have built an MFG 5 with eight outputs several times for one customer. In fact, every second CUSTOM LINE generator constitutes a new system, one we have never before put together in that particular way before. We have a lot of experience now in expanding our technology toolkit." The same also applies to the "adjustment range," which refers to the ratio of the smallest inductor to the largest, or the range of frequencies which can be operated with a single generator; eldec can cover a very wide range.

Stable processes ensure quality

To ensure the quality and stability of the technology, eldec uses a high degree of vertical integration, more than 90 percent. All the central components are designed in Dornstetten and assembled by hand.

Perfectly positioned

All in all, eldec believes that its highly customizable generator range puts it in an ideal position in the marketplace. "We have at our disposal a huge pool of knowledge gained from practical experience, we are continuously improving the technology, and we only supply components that are optimally configured and robust," Krötz said. "On top of that, our high level of vertical integration gives us the advantage of quick reaction times and high flexibility. That is a sought-after quality, especially for heating applications, which are often very specialized."

eldec Generators CUSTOM LINE

Induction heating is used in a variety of applications, ranging from shrinking, soldering, brazing, expanding, and joining through to melting, annealing, and induction surface hardening

Read the full article on the EMAG eldec dedicated site.