İndüksiyon Isıtma Sistemleri

INDUCTION HEATING SYSTEMS

Ais Engineering – Your Solution Partner in Induction Heating Systems.

TECHNOLOGY

Direct Precision Heating
Ideal Temperature Control
Saving electricity

PRIVILEGES

Short Heating Time
High Energy Efficiency
High Work Efficiency
Easy Temperature Control

Ais Engineering

What is Induction Heating?

The basic logic of induction heating can be considered as electromagnetic heating. In the induction heating process, eddy currents are generated in the heated material using the electromagnetic induction principle and electrical heating of the material is carried out in a non-contact manner.

In the induction heating method, since the heat is generated inside the working material, heating is much more efficient than traditional resistors. In other words, heat losses are reduced with induction heating and thus the total heating efficiency is increased.

Working Principle of Induction Heating

Advantages of Induction Heating

Today's industrial world has to quickly adapt to rapidly changing technology, and the induction heating system creates many innovations and advantages over other traditional heating methods. For example, induction heating is more energy efficient and naturally environmentally friendly compared to other heating methods, and it does not produce carbon dioxide emissions. It contributes to environmental friendliness by significantly reducing the total heat exposure of the material in the production line. With induction heating, industrial companies can maximize environmental, process flexibility and electrical efficiency, while also providing continuous solutions for the production of higher quality products.

Long Service Life: No heat is generated on the induction heating coil and the temperature of the heating coil does not reach high temperatures, so its service life is long. No maintenance and replacement costs are required. The service life is approximately 6 years when the system operates at full capacity and 24 hours a day, without requiring any maintenance costs.
Safe/Reliable Use: The inside of the cylinder/bucket is heated by high-frequency electromagnetic effect, and the heat is fully utilized and there is basically no loss. Heat is generated in the inner part of the heating body, and the surface temperature is slightly higher than room temperature. Therefore, it does not require temperature protective measures on the outside.
High Efficiency and Energy Saving: With direct induction heating and magnetic energy, the time to reach the desired temperature is very fast and the preheating time can be up to 60% faster than with resistance. Most importantly, at least 30% electricity savings are achieved compared to traditional resistance heating methods.
Accurate Temperature Control: The coil and the cylinder itself do not heat up. In this context, the thermal resistance and thermal inertia are very low, the internal temperature of the material cylinder is consistent, and the temperature control is real-time and accurate. Therefore, product quality and production efficiency are high.
Good insulation: The area around the hive/cylinder is covered with quality insulation material. At the same time, all surfaces of the cylinder are wrapped with a special high-voltage cable resistant to high temperatures. There is no direct air contact with the outer perimeter of the cylinder.
Improve Work Environment: There is no heat loss, and the surface temperature of the heated equipment is low enough for human touch. This improves the working environment of the production site, can improve the working performance of production workers and reduce the cost of ventilation.
Generally, Induction heater has the characteristics of energy saving, high efficiency, long life, high accuracy etc. It has advantages. Induction heater is more suitable for production. In addition to improving production efficiency, production costs are greatly saved, thus increasing profits. AİS Engineering induction heaters provide 30% - 50% energy savings.

Disadvantages of Heating with Conventional Resistance

Large Heat Loss: Traditional heating mode, resistance wire winding, inner and outer double-sided heating circle, transfers heat to the cylinder (sleeve) from the inner side (closer to the cylinder part), and since the air is heated from the outer side, electricity is wasted due to heat loss.
Environmental Temperature Increase: Due to the large amount of heat loss and increase in ambient temperature, some businesses have to use air conditioning to reduce the temperature.
Large Space Occupancy, Short Service Life: Since the resistors operate continuously at high temperatures, their lifespan is very short. The service life of resistors commonly used in cylinder or barrel heating is approximately one year.
Price/performance: Heating with resistance is the easiest and simplest heating method. But today, with the development of technology, people's demand for heating is also increasing. Nowadays, in addition to a good heating effect, sufficient energy saving and environmental protection are also needed. Obviously, the performance of the traditional resistance heater is not suitable for the current technical requirements and price/performance.

With resistance Heating Comparison

There are several methods other than induction heating to heat an object or material. Some of the more common industrial applications are gas furnaces, electric furnaces and salt baths. These methods all rely on heat transfer from the heat source to the material through convection and radiation. In short, after the surface of the product is heated, the heat is transmitted to the product by thermal conduction.

Products heated by induction do not use convection and radiation heating methods to conduct heat to the product surface. Instead, heat is generated by current flow through the material and the material is heated by thermal conduction.

One of the most important advantages of induction heating is that there is no need to use a cooling fan for temperature control. Since the temperature cannot be kept constant at the desired value in traditional resistance heating, a cooling fan is used for temperature control. In induction heating, temperature control is very easy since heating is done with electrical current and no extra cooling fan is used.

In resistance heating, the heated barrel or cylinder exterior is in direct contact with air. Since most of the heat comes into contact with air, energy efficiency is very low. In induction heating, temperature insulation material is placed outside the barrel/cylinder. This insulation material alone saves 20% of electrical energy. In addition, since the temperature outside the barrel/cylinder is very low, even the heated area can be touched with your hand.

One of the most important advantages of induction heating is that the entire target heating area is heated, producing a more uniform material structure. In traditional heating methods, heat cannot be transmitted at the same rate at every point within the material. However, in induction heating, the induction winding completely surrounds the hive or similar heating area. This ensures equal distribution of heat to the heated material.

In addition, since induction heating uses the thermal heating method, the material is heated from all aspects, not from its outer surface. Thanks to this thermal heating method used, precise settings such as depth adjustment can be made in the heating of the material by adjusting the electrical frequency, which means that materials that require better quality and precise heat adjustment can be easily produced.

Adjusting the Heat Depth by Adjusting the Frequency in Induction Heating

General Characteristics of Induction Heating

Features	Induction Heater	Traditional Resistance Heater
Heating Principle	Electromagnetic	Resistance Wire
Heated Part	Heated material directly in the cylinder/sleeve	Outside of Cylinder/Sleeve Wall
Surface Temperature and Safety	Max. 60° Degree temperature, heated surface can be touched	The temperature is the same as the heated material inside the cylinder, and it is dangerous to touch the outside of the cylinder.
Heating Efficiency	High Efficiency 95%, fast heating time	Low Efficiency 30%-50%, slow heating time
Saving electricity	30%-50% Electricity Saving	No Electricity Saving
Temperature Control	High Sensitivity	Low Sensitivity
Lifetime	Between 5-6 Years	Between 1-2 Years
Work environment	Normal Temperature	High temperature
Price	Cost effective, installation cost is amortized within 6-10 months	Low

Installation Cost

In general, an induction system initially costs roughly five times as much as traditional heater strips, but this cost difference may decrease later. For example, depending on the daily electrical energy used, the energy savings achieved in just 6-9 months for a machine that heats induction hives covers the entire installation cost of induction heating. In addition, the higher the efficiency of the machine and the larger the cylinder/barrel, the greater the electricity savings will be.

Additionally, it should be noted that new machines have potential savings such as less wiring, less frequent maintenance, no need to keep replacement heater bands in inventory, reduced downtime, and even improved product quality.

Sectors Served

Induction heaters are mainly used in plastic (rubber) injection machine, extrusion machine, blown plastic film machine, bag machine, wire drawing machine, plastic pipes, cables, etc. Used in areas. Induction heating is a rapid form of heating in which heat is induced directly into the part being heated (for example, the barrel). Induction heating is a non-contact form of heating. A typical induction heating system consists of induction heating power supply, induction heating coil. The induction heating power supply sends alternating current through the induction coil, creating a magnetic field and thus producing heat.