Objective Heating the ends of six wires on a starter motor to remove the electrical varnishes
Material Starter motor with six wire bundles, each wire consists of 3
wires 0.04 (1.0mm) diameter each
Temperature 1202 F (650 C)
Frequency 297 kHz
Equipment DW-UHF-20kW induction heating system, equipped with a remote workhead containing two 0.5F capacitors for a total of 0.25 F.
An induction heating coil, designed and developed specifically for this application.
Process A six position coil with three turn helical coils at each position is used to simultaneously heat 0.8 (20mm) length at the end of each copper wire bundle for 2.5 seconds to burn off the electrical varnish.
Results Induction heating provides:
Hands-free heating that involves no operator skill for manufacturing.
Multi-position coil provides simultaneous heating for quicker production times.
Complete removal of varnish improves electrical performance of connections.
Even distribution of heating.
Objective To heat a nitinol spring assembly to 800F (426.6C) for shape setting application
Material 0.018 (.457mm) Nitinol wire wrapped around a 0.08 (2.03mm) Nitinol mandrel 15 (381mm) long
Temperature 800F (426.6C)
Frequency 270 kHz
Equipment DW-UHF-6 kW induction heating system, equipped with a remote workhead containing two 1.5F capacitors for a total of 0.75F
An induction heating coil, designed and developed specifically for this application.
Process A six turn split helical coil is used to heat the nitinol wire assembly to 800F (426.6C). The assembly is pulled through the coil at a steady rate to evenly heat a 1/2 (12.7mm) section of wire continuously in 4-5 second.
Results/Benefits Induction heating provides:
Hands-free heating that involves no operator skill for manufacturing
Even distribution of heating along the wire
Wire is heat treated on the winding machine, eliminating a secondary process
Desired heat treating temperature can be adjusted by varying the time the wire assembly spends in the coil.
Objective Heating stainless steel disc & tantalum disc to 1400F (760C)
Material Stainless steel and tantalum discs approx 1/2 (12.7mm) diameter. End product is radioactivity counting plate
Temperature 1400 F (760C)
Frequency 350 kHz
Equipment DW-UHF-3kW induction heating system, equipped with a remote workhead containing one 0.66F capacitor
An induction heating coil designed and developed specifically for this application.
Process A three turn helical coil is used to heat the discs to 1400 F (760C). The stainless steel disc reaches temperature in 3.5 seconds, the tantalum disc reaches temperature in 1.7 seconds. The heat up time can also be varied by changing the
distance between the coil and the part to suit the application fixturing design.
Results/Benefits Induction heating provides:
Hands-free heating that involves no operator skill for manufacturing
Precise even heat without out the use of flame or oven
Objective To preheat a steel pipe to 500F (260C) before welding.
Material Steel shaft assembly 5 to 8 OD (127-203.2mm) with a 2 (50.8mm) heat zone.
Temperature 500F (260C), if higher temperatures are required, heat time can be increased.
Frequency 83 kHz
Equipment DW-HF-120kW induction heating system, equipped with a remote workhead containing eight 1.0 F capacitors for a total of 8 F.
An induction heating coil designed and developed specifically for this application.
Process A multi-turn two position channel C coil, adjustable on a busbar is used to heat the desired heat zone. The coil is adjustable to fit various diameter pipes. The shaft is rotated in a fixture and heated for 3 minutes to achieve a temperature of 500F (260C).
Results/Benefits Induction heating provides:
Preheating prevents shock to shaft which eliminates cracking in the welding phase.
Hands-free heating that involves no operator skill for manufacturing.
Even distribution of heating between the shank and the sleeve.
Objective Sintering copper powder to a stainless steel shaft
Material Steel shaft & shell assembly, approx 2 (50.8mm) diameter, 2 (50.8mm) tall, copper powder
Temperature 1600 F (871 C)
Frequency 54 kHz
Equipment DW-HF-45kW induction heating system, equipped with a remote workhead containing eight 1.0 F capacitors for a total of 8.0 F.
An induction heating coil designed and developed specifically for this application.
Process A four-turn helical coil is used to heat the assembly for five minutes. This provides slow, even heat for good penetration through the shell into the powder.
Results/Benefits Induction heating provides:
Even heat through the shell to sinter the powder.
A method that is easily integrated into an automated production line. The design may be adapted to accommodate the indexed heating of several assemblies at the same time.
Hand- free operation that involves no operator skill for manufacturing.
Objective Heat steel to help bond an injection molded piece and help the reflow.
Material Steel motor body, 60 x 60 x 27 (2.4 x 2.4 x 1.1) mm(in)
Temperature 260C (500F)
Frequency 237 kHz
Equipment DW-UHF-20kW induction heating system, equipped with a remote workhead containing a total 1.5 F.
An induction heating coil designed and developed specifically for this application.
Process/Narrative A two-turn binocular coil is used to simultaneously heat two steel motors prior to the injection molding process. This helps increase the bond strength between and reflow the plastic.
Results/Benefits Induction heating provides:
Quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times.
Significantly reduced footprint
Reduced handling due to location of the induction coil in proximity to the injection molding machine.
Objective Prior to cutting, heat a short section of a hardened steel cable coated with a polyethylene sheathing.
Material Multi-strand braided stainless steel cable 0.5 in. (1.27 cm) OD enclosed within a polyethylene sheathing
Temperature 1800 F (982) C
Frequency 40 kHz
Equipment DW-HF-60kW induction heating system, equipped with a remote workhead containing four (4) 1.0 F capacitors (for a total of 1.0 F).
An induction heating coil designed and developed specifically for this application.
Process A three-turn helical coil is used to heat the cable in approximately 2 seconds. After the power is turned off, the
heat is then transferred to the sheathing.
Results/Benefits Induction heating provides a quick, precise repeatable method
to reach the high temperature required. It is a very efficient heating method.
Objective Provide a hermetic seal of glass enclosed resistor to a lead
Material Resistor
Kovar rings, 0.1 inch (0.254cm) diameter
Glass tube slightly larger than 0.1 inch (0.254cm) diameter, 0.5 (1.27) inch length
Metal lead
Temperature 900 F (482) C
Frequency 324 kHz
Equipment DW-UHF-6kW induction heating system, equipped with a remote workhead containing two (2) 1.5 F capacitors (for a total of 0.75 F).
An induction heating coil designed and developed specifically for this application.
Process A three turn concentrator plate coil is used to heat the Kovar ring for 500 milliseconds. This causes the glass to melt and seal one side of the resistor. The resistor is then turned over and the process is repeated to seal the other side using a second Kovar ring.
Results/Benefits Induction heating provides precise, consistent heat to very
small parts resulting in repeatable, quality seals.
By heating with medium frequency, arcing (which occurs at high frequencies) is avoided.
Objective Temper a spring by heating it to 300C (570F) in 2 4 seconds
Material Stainless steel AISI 302 springs- different length from 60 to
110 mm – outer diameters 8 mm.- wire diameter from 0.3 to 0.6 mm
Temperature 300C (570F)
Frequency 326 kHz
Equipment DW-UHF-6kW induction heating system
remote workhead, two 0.33F capacitors (total 0.66F)
multi-turn C-channel coil developed for this application
Process Springs are mounted on non-metallic mandrels to facilitate loading and unloading and are placed inside the coil (picture). Power is applied for 2 4 seconds, completing the tempering process. The C-channel distributes the heating evenly and enables the convenient staging and removal of the springs.
Results/Benefits Efficiency: Energy is applied directly to the springs only; surrounding air and fixturing are not heated.
Precision: temperature and duration of process are controlled Convenience: method integrates into a continuous process
Objective Expand powder into solid form for use in crash helmets
Material Microspheric powder
Aluminium chamber 110mm (4.3 in.) diameter x 35mm (1.3 in.) deep used to hold powder
Temperature 150 oC (302 oF)
Frequency 54.5 kHz
Process Time 20 seconds
Equipment . DW-HF-35 kW induction heating system, equipped with a remote workhead containing (4) 2.6 F capacitors (for a total of 2.6 F).
. Two pancake coils 110mm (4.3 in) dia. with 45mm (1.8 in.) gap, in a headphone configuration designed and developed specifically for this application.
Process The bottom of the susceptor chamber is sprayed with a release agent and microspheric powder is added to the chamber. The chamber is heated for 120 seconds to reach 150o C (302o F) changing the powder into solid form. It is then allowed to air cool to 70o C (158o F) and removed from the chamber.
Results/Benefits Induction heating:
. reduces cycle time for increased production
. energy efficient – only heating the part allowing small production runs
. is very flexible allowing a variety of molds to be used
