Induction Heating Fundamentals

Prof. Dr.-Ing. Bernard Nacke Institute of Electrotechnology Leibniz University of Hanover (Germany)

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

1. Principle of induction heating 2. Advantages of induction heating and typical applications 3. Mathematical equations 4. Skin effect, proximity effect 5. Influence of frequency and electromagnetic penetration depth on induced power 6. Influence of material, non-linear material properties 7. Influence of work-piece geometry
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Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Magnetic flux / induction effect

Induced current

Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Principle of induction heating

Heating of a steel tube

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Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Heat generation without flame (variable atmosphere, vacuum) High power densities High process temperatures High heating-up speeds Direct heating within the work-piece High thermal efficiencies Excellent control of induced power Many chances for new technologies using induction
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Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Classical applications

Melting of metals in induction furnaces

(foundries, metal plants)

Heating of metals for deforming (forging, rolling) Heat treatment of metals like hardening and annealing Welding of steel tubes

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

New applications

Heating of metallic strips and sheets (longitudinal field,

transverse field)

Thixoforming, thixocasting Melting in cold crucible Stirring of metallic melts before solidification Electromagnetic processing of semiconductor melts for the
production of semiconductor wafers and solar cells

Skull melting of oxides and glasses Combined induction pre or post heating and laser welding
Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

The flow field can be described by the Navier-Stokes equation

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Current density distribution in a cylindrical work-piece (approximation) Electromagnetic penetration depth

The exponential distribution of current and magnetic field is exactly valid only for plane surfaces (approximately valid for cylinders for d/ > 4)
Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Inductor efficiency of a cylindrical arrangement of inductor and work-piece as function of work-piece diameter to penetration depth ratio
Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Quelle: RWE-Information Induktive Erwrmung

Induced power density dependent on the ratio of d/ for constant frequency and variation of the work-piece diameter
Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Temperature distribution for heating of cylinders

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Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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For two neighbour current conductors with different current directions eg. forward/back current in conductors or current of coil and work-piece

a displacement of currents occurs that currents flow at shortest distance between conductors (Principle of lowest inductivity or lowest magnetic energy)

Quelle: RWE-Information Induktive Erwrmung Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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movingdirection

Ratio of strip thickness to penetration depth d / > 3 .. 5

movingdirection

d/ < 1

Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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Current density in the work-piece in A/m: Electromagnetic penetration depth in m: Power in the work-piece in W: Electromagnetic pressure in melts: Height of meniscus in m: Dependence of meniscus height on frequency: Dependence of flow velocity on frequency: Total power in kVA: Active power in kW: Reactive power in kVA: Power factor: Electrical efficiency:
Prof. Dr.-Ing. B. Nacke / Institute of Electrotechnology, Leibniz University of Hannover

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