Bio: Dr. Girish Dahake is Ambrells Senior Vice President, Global Applications. He has over 25 years of induction experience and leads a worldwide team of induction application experts at Ambrells applications laboratories. He holds patents, has authored numerous papers, and frequently presents at professional conferences on topics such as nanoparticle heating, heat staking and general induction heating. Dr. Dahake holds a Ph.D. in Mechanical and Aerospace Engineering from the University of Rochester.
Induction heating isnt a new technology, yet it still isnt widely known and adopted within the manufacturing industry. To learn more about this technology, we met with Dr. Girish Dahake of Ambrell to discuss the basics of induction heating and its impact on the industry.
Q: Can you explain how induction heating works?
A: Induction heating uses magnetic fields to transfer energy. An induction machine creates an alternating current that flows through the induction heating coils and creates a magnetic field around the copper coils. This magnetic field and the alternating current create eddy currents in metal parts.
Basic knowledge of electricity: if you can get a current flowing in a part, it produces heat. So, induction heating relies on the transfer of that electric energy through the magnetic field to the part to create that heat. Compared to other forms of heating metal, induction is unique because it doesnt require a transfer medium. Its actually similar to the energy that we get from the sun. Thats the magical aspect of induction.
Q: What are the benefits of induction heating?
A: The biggest benefit of induction is that its very selective in its heating. So, it can heat a small section of a part without having to heat the entire part, and that only requires a minimal amount of energy. This makes the whole induction heating process very efficient.
Another benefit of induction is that its extremely repeatable and reliable. Once you set up an induction process, it wont suddenly stop working. Induction works repeatedly day after day, year after year, which is beneficial to manufacturing engineers because they dont have to spend time fixing and debugging induction machines just to make them work.
Induction is also easily controlled. If somebody wants to heat a part to degrees but no more, induction is able to get up to that degrees and stay there. That kind of control is important in medical applications, aerospace applications, etc. to ensure parts are properly made and safe.
All of these benefits combined make induction extremely efficient. Not only regarding energy consumption, but also in cost per part. Companies want to make their parts cheaper. Induction is one of the cheapest ways to make parts for production.
Q: While were on the topic of energy efficiency, can you describe some of the green benefits of induction heating?
A: Compared to heating methods that use fossil fuels, where something is burned to create heat, inductions input is electrical energy. So, its not producing any combustible gases, flames, or smoke. With induction we dont produce any residue, which makes it a green technology. And since nothing is being burned, this also makes induction heating safer. There are no dangerous fuels to transport and store, and no harmful UV radiation is being produced.
Q: With all these great benefits, why isnt everyone using induction heating?
A: The biggest challenge in the industry is companies inability to change from the method theyre using to heat parts. To change their process is a big challenge. If somebody needs to create a new process, its easy to choose induction because theres so many advantages. But if you already have all your infrastructure and operations around another heating method, then its hard to get rid of all that and go to induction unless you have an extremely pressing reason. Typically, with new installations, induction is the easy choice, but with existing installations companies have to make a commitment to get rid of their current heating method.
Q: What other options is induction heating competing with?
A: Fire is still the predominant heating method in the industry today, so a lot of installations that were set up decades ago use flame. Flame is one of the most common methods to heat parts because its easy to see, easy to implement, and everyone is familiar with it.
Other installations include ovens and furnaces. In those kinds of installations, the entire part gets heated. Usually, parts are heated to join two pieces together. So, before theyre joined, they have to be held in place. Now the holding fixture also ends up going into the oven or furnace and getting heated, which leads to more energy consumption.
So, for heating methods competing with induction, theres open flame, ovens and furnaces, and then theres also lasers. Lasers are used to cut metals; their cost makes them impractical to use for generalized heating. So, these are the main competing heating methods in the industry.
Q: How is induction heating different from these options?
A: One main difference is safety. Induction heating is safer because, unlike other heating methods, youre not burning anything. Another difference is that induction is efficient. With other heating options, a lot of the heat escapes and is used inefficiently. With induction these things are a non-issue because the heat is going directly from the induction source into the part. Theres no heat in the air. So, induction is very efficient compared to these other forms of heating.
Another difference is control. A lot of applications require parts to be heated at an extremely fast pace but only to a certain level. Induction can quickly heat a part to your desired temperature and then stop there, which is very difficult to do with the competing technologies.
Q: What are some applications that are a good fit for induction?
A: There are so many good applications for induction. One that everyone is probably familiar with is the aluminum foil seals on plastic bottles. Those are all sealed with induction heating. Another application is refurbishing turbine blades in aircraft engines. Induction heating is used to preheat the blades to help rebuild them. Theres a limited window of time for this process to be completed, so the speed of induction heating allows the turbine blades to be quickly refurbished.
Induction heating is also used in a number of different electric vehicle applications, such as manufacturing rotors and fuses. For headlights and taillights, induction is used to heat metal inserts that are pushed into the lights plastic encasing to anchor it to the frame of the car. A lot of electric vehicle battery manufacturing processes also use induction heating.
One particularly unique application that interests me is in the medical field there are researchers using induction heating to kill cancer and tumor cells in the human body. Which is a very different application of induction that involves injecting small particles into the tumor or cancerous cells and then heating them to kill off the circulation in those cells. So that is very exciting and as it comes to fruition in the marketplace, I think humanity will benefit a lot from this type of research.
Q: Are there any limitations or constraints to induction heating?
A: One of my toughest jobs is to say no to induction applications, but there are certain cases where other forms of heating are better suited. For example, induction is not a good fit for metal cutting. Lasers are a very good fit. Even though induction might be able to do it, it's not the right fit for that process. Everything has to be evaluated on a case-by-case basis to determine if induction is the right fit.
Ambrell does have an applications lab where we can experiment for customers and try to eliminate some of that risk when incorporating a new product/process. We know induction heating helps cut costs, doesnt release emissions, and is a safe and efficient technology. Now were trying to get that knowledge out to the industry.
Q: What does the future look like for induction heating in the manufacturing industry?
A: I believe more and more companies are going to implement induction in their manufacturing processes whenever they need heat. Making parts with induction costs less, and inductions capabilities are so far ahead of other heating methods. Most of the time people are just not aware of the advantages of induction. I think the more people find out about it, the more it will become a no-brainer. When people say, I have this decision point should I buy an oven or an induction machine?. Theyre going to go for induction because its safer, more efficient, and better for the environment.
If you are interested in finding out more about induction heating,If you are interested in finding out more about induction heating, reach out to Ambrell to learn about their induction heating solutions. Or if youd like to meet with them face-to-face, attend SOUTHTEC and find Ambrell at booth #733.
Induction heating is a process that uses electromagnetic induction to heat conductive materials, such as metals and semiconductors. The heating is caused by eddy currents, which are induced in the material by a rapidly changing magnetic field. The frequency of the magnetic field is typically in the range of 10 kHz to 1 MHz, and the power level can be adjusted to control the rate of heating. The temperatures are as low as 100 ºC (212 °F) and as high as °C ( °F) .It can be used in brief heating processes that are on for less than half a second and in heating processes that are on for months.
The Benefits of Induction heating over other heating methods, such as:
* Efficient, with up to 98% of the energy being converted to heat.
* Fast, with the material typically reaching the desired temperature in seconds.
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* Precise, with the heating area being limited to the area within the induction coil.
* Safe, with no emissions or fumes or flame
Extended Life of Fixturing due to precise heating
Induction heating is a versatile and efficient heating method that is used in a wide variety of applications. It is a safe, precise, efficient, and clean process that offers several advantages over other heating methods.
Induction heating is used in domestic and commercial cooking, and in many applications, such as melting, heat treating, preheating for welding, brazing, soldering, curing, sealing, shrink fitting in industry, and in research and development.
Induction heating is used in a wide variety of applications, including:
* Metalworking, such as hardening, annealing, and welding
* Plastics processing, such as melting and forming.
* Food processing, such as cooking and pasteurization.
* Medical applications, such as surgical sterilization and cancer treatment
Difference between Induction Heating and Resistance Heating
Heating is a process of increasing the temperature of a body to an acceptable level by using thermal energy. The mechanism involved in heating is generally referred to as a heating system.
When the process of heating is performed by using the electric current, i.e. the electric current is converted into heat energy by employing a suitable mechanism called the electric heating. The principle behind the electric heating is the heating effect of electric current which states that when an electric current flows through a conducting medium, the medium resists the flow of this current which results in the rise in temperature of the medium, i.e. the heating of the medium.
Today, different methods of electric heating are available like resistance heating, induction heating, arc heating, dielectric heating, etc.
Basis of Difference
Induction Heating
Resistance Heating
Definition
The type of electric heating in which object is heated by the process of electromagnetic induction is called induction heating.
The type of electric heating in which object is heated due to only the resistance of the material of the object is called resistance heating.
Principle of heating
The electromagnetic induction is the principle behind the induction heating.
The power loss in resistance (I2R loss) is principle used in the resistance heating.
Types
There are two types of induction heating namely, direct-induction heating and indirect induction heating.
There are two types of resistance heating namely, direct resistance heating and indirect resistance heating.
Current carrying part
In case of induction heating, the electric current flows through a coil of an electromagnet of the induction heater.
In resistance heating, the electric current flows through a wire of high resistance to produce heat.
Heating part
In induction heating, the heat is directly produced in the object to be heated by the electromagnetic induction.
In resistance heating, the heat is produced by a resistance wire and then transferred to the object to be heated.
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