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Induction Bending

Induction Bending Systems - Overview

Induction bending refers to the use of the induction heating principle to heat a metal part to make it easier to bend.

As the heat is generated very quickly within the component itself very precise control is possible over the heated area thereby reducing scaling. The control of the temperature and heated zone ensure a predictable bend can be produced.

The principle advantages of induction heating over traditional methods such as gas furnaces are as follows:

• 1) Precise control over the hearted zone.
• 2) Accurate control of the target temperature.
• 3) Significantly reduced energy costs due to the efficiency of the induction heating process. The heat is confined to the area of the bend so only this section is heated. Unlike gas furnaces the unit is ready immediately and does not need to be pre-heated or run even when empty.
• 4) Health and safety due to the removal of naked flames and pressurised gas storage systems from the process.
• 5) Easily repeated results and de-skilled setting and operating procedures.
• 6) Better quality product due to reduced scaling and better quality control due to the predictable nature of the process.
• 7) Reduced scrap due to reliability and repeatability of process.

All systems feature the same principle elements as follows:

• 1. An Induction Power Unit - The power and frequency of this unit is selected based on a variety of parameters including throughput, component thickness and the desired heated length
• 2. A work Station to support the Work Coil - Typically air blast coolers, refrigeration chillers and water to water cooler are utilised subject to climatic conditions and local requirements.
• 3. The Work Coil - Constructed from high conductivity copper and protected by a heat proof box.
• 4. A Mechanical Materials Handling System - To manipulate the components.
• 5. Cooling System - The cooling system will normally be a split type where the cooling water for the generator is on one circuit and the quench is cooled on a separate circuit. Typically air blast coolers, refrigeration chillers and water to water cooler are utilised subject to climatic conditions and local requirements.
• 6. Temperature Control System - A non-contact infra red pyrometer to monitor or control the temperature.

Typical applications include railway clips, fork lift forks, and progressive tube bending systems.

Induction Bending - Case Study

Application - Confidential.
Component Details - Round bars 15mm to 25mm diameter 100mm to 350mm long.
Process Requirement - Heat bars to 900°C at rate of between 15 second and 25 seconds.
Induction Equipment - Inductelec D-Type 350kW 10kHz power unit.
Feed System - IHG 250 HBFS Horizontal progressive bar feed system.

The unit features a variable speed pinch roller system to push the bars one behind the other through the tunnel type work coil. Bars are fed from an inclined magazine with a capacity for 30 minutes work.

The system featured PLC control with a recipe based setting system utilising a Mitsubishi HMI with error trapping on all critical parameters. Work coil, IWC 350 air-blast cooler. Non contact infra red pyrometer monitoring system with eject for incorrectly heated parts.

Please browse our website for more information about Induction Bending Applications and then contact us on 0114 272 3369 to speak to a member of our team or e-mail us on info@inductelec.co.uk.