Induction heating and induction heating capacitor

The induction heating is clean and fast. It also highly repetitive; once the induction heating/melting equipment has been set up, the work-piece like aluminum/iron/copper/gold//steel/silver/gear/shaft etc can be heated with identical results. 

Application scenarios of induction heating

1. 
   1.  The automotive industry for treating bearings, brakes, drive trains, gears joints and shafts. Frames, seats, bumpers and steering wheels are also heat treated.
2. 2.  The bus and truck industry for similar, albeit physically larger, applications and the ship-building industry for larger still; It is also used for repairing and reshaping damaged hulls. The commercial and recreational marine engine industry uses induction heating processes in production.
3. 3.  The sports and fitness industry for golf clubs, goal posts and exercise equipment.
4. 4.  The wind-turbine industry for gear-handling systems.
5. 5.  The aeronautics and aerospace industries for heat treating components and producing special alloys.
6. 6.  The oil and mining industries for pipe and tool manufacture.
7. 7.  The railroad industry for an array of locomotive parts.
8. 8.  The commercial, residential and industrial construction industries for the production of structural sections.
   
   

What need to know when you plan a new induction heating/melting machine? 

1. 
   1.  What are work-pieces that need heat treatment? (application scenarios above description)
2. 2.  What is the operating frequency and power rating (in kW or kVAR) of your power supply?
3. 3.  Are you dealing with a series or parallel resonant circuit? 
4. 4.  IGBT or Thyristor control system?
5. 5.  Air-cooled or water-cooled setup?
6. 6.  What type of the induction heating equipment? ( such as large industrial heat treatment and processing systems, mobile heat generators, solid state welders, modular forging systems)

With the basic requirements, Flair Electronics can work out the exact capacitor specifications and cooling requirements you need. We provide with optimization solution of induction heating capacitor bank. The optimal suitable capacitors are designed in order to have minimized internal losses so that it can work in induction heating circuits with high frequencies, by very high current and high working voltage. The key point is that water-cooling capacitor is popular used in induction heating machine because it can achieve quite high working rated power in range from hundreds of kVA to few MVA.

Induction heating capacitor Features

Applying for high temperature polypropylene film dielectrics, exceptionally low Equivalent Series Resistance (ESR) to prevent internal overheating, and robust water-cooling capabilities to handle continuous multi-hundred amps loads and reduce the temperature rise of capacitor.

Induction heating capacitor selection tips

1. 
   1.  Choose a capacitor rated at least 20% higher than your system’s peak operating voltage.
2. 2.  Dictates your resonant frequency  . Standard induction heating applications typically use capacitance values ranging between 0.1μ F and 100μ F
3. 3.  Ensure the capacitor is specifically rated for the frequency of your induction heating machine, such as medium frequency for melting or high frequency for precise heat-treating/welding.  
4. 4.  Apply for multiple capacitors in parallel to achieve the required capacitance
5. Most high-power industrial induction furnace apply for liquid-cooled capacitors. a clean water-cooling circulation system is mandatory, make sure outlet water temperatures as specified by capacitor makers, usually <45℃. The improper Water-flow will cause rapid internal failure of capacitors.
6. 5.  When constructing induction heating capacitor bank, use multiple capacitors in parallel to achieve the required capacitance. Connect the work coil leads to opposite ends of the capacitor bank bus bar so all capacitors share an equal current load, rather than having the front capacitors take the brunt of the heat.

Essential parameters of induction heating capacitor