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Medium Frequency Capacitors for Inductive Heating Circuits - China Suppliers & Factory Solutions
General introduction
The induction heating&melting capacitor is specially designed for induction heating furnace. It generates current inside the conductor through a high-frequency electric field to achieve rapid heating effect. This capacitor has an efficient energy conversion rate and enable to convert the input electrical energy into heat energy very fast, thus achieving rapid heating/melting of the metals.
| Dielectric material | PP film |
| Insulation liquid | biodegradable,non-PCB |
| Maximum allowable voltage | Rated voltage×1.05 (12 hours/day) |
| Maximum allowable current | Rated current×1.15 |
| Tanδ | Less than 0.1%(1W/Kvar) |
| Ambient air temperature | -20~40℃ for natural cooling or force ventilated; -20~50℃for water cooling |
| Inlet Cooling water temperarture | lower than 30℃ |
| Outlet cooling water temperature | lower than 45℃ |
| Installtion | Indoor, please advise if you want to install horizontally, special design requires for Horizontal position。 |
| Case | Alumium case |
Working principle
The working principle of the induction heating/melting capacitor is based on the principles of electromagnetic induction and capacitor energy storage. When the high-frequency AC power supply is connected to the capacitor, the high-frequency electric field will be generated inside the capacitor. This high-frequency electric field generates an induced current on the surface of the metals being heated. We call this vortex as well, the vortex/currents covert electrical energy into thermal energy, thus enabling rapid heating happens in the whole induction furnace system.
The capacitor design structure
Considering the various factors,such as capacity, working voltage, frequency, current etc. The capacitor consist of electrode, capacitor core and insulation materials, cooling water tubes.
Electrode: it connect to the power system, so the current will pass through smoothly.
The insulation materials: It guarantee the capacitor safety, prevent the capacitor from the electric leakage or breakdown.
Cooling water tubes: the cooling water help to control the capacitor temperature.
The application superiority of the induction heating capacitors
Fast heating rate: achieve fast heating rate through the induced current being generated by high-frequency electric field.
High energy efficient: convert most of electric energy to heat energy, less energy loss.
Reliable: apply for mature insulation and heat dissipation technology, the equipment is capable of working continuously for long time.
Environmental protection: no need fuel, no exhaust gas generated during the production.
Reasonable design and selection can optimized the matching of water-cooed capacitors and medium-frequency furnaces, further improving energy conversion and utilization efficiency.
Extend equipment life: the water cooling design make the whole system achieve good heat dissipation, keep the safety environment of metal metallurgy.
Future prospect
In order to obtain higher energy conversion efficiency and improve the electric energy efficiency, a high input and output power factor. With the development and the application of power electronics, resonant inverters in the induction power supply circuit through the power device to achieve the soft switching, so the induction heating power system will be toward large capacity and higher power, those technologies need to be further solved.
The development trend of induction heating technology is more high-power and large-capacity:
High-frequency; Low power consumption, high power factor;
Intelligent and digital control;
Heating technology no oxidation etc.
Factory operation procedure
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1. capacitor cases
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1. cooing water tubes-1
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1. cooling water tubes-2
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2. winding capacitor core-1
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2. winding capacitor core-2
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2. winding capacitor core-3
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3. soldering and assembly
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3. solering core
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4. Test of intermediates
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5. sealing the case
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6. Vacuum oil filling process-1
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6. Vacuum oil filling process-2
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6. Vacuum oil filling process-3
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7. leak test
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8. Ex-factory test
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9. packing and delivery
Frequently Asked Questions
Q1: What is the main function of an induction heating and melting capacitor?
A1: It is specially designed for induction heating furnaces. It generates current inside the conductor through a high-frequency electric field to achieve rapid heating and melting of metals.
Q2: What materials are used for dielectric and insulation in these capacitors?
A2: The capacitor is built with PP film as the dielectric material and a biodegradable, non-PCB insulation liquid.
Q3: What are the cooling options and their corresponding ambient temperature limits?
A3: The capacitor supports natural cooling or forced ventilation (ambient air temperature -20 to 40℃) and water cooling (ambient air temperature -20 to 50℃). For water cooling, the inlet temperature should be under 30℃ and the outlet under 45℃.
Q4: What are the key components in the capacitor's design structure?
A4: The structure consists of electrodes for power connection, a capacitor core, insulation materials to prevent breakdown or leakage, and cooling water tubes to manage temperature.
Q5: How do these capacitors improve the overall system performance?
A5: They provide fast heating rates, high energy efficiency with minimal loss, reliable continuous operation, and optimized power matching. The water cooling design also helps extend equipment life.
Q6: What are the future trends for induction heating technology?
A6: Future trends are focused on high-power, large-capacity, and high-frequency systems. This includes reducing power consumption, increasing power factor, implementing intelligent/digital control, and developing oxidation-free heating.