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UltraFlex induction heating a coiled carbon-based music wire to 850°F (~454°C) within 1 sec
This induction heating test allowed the customer to confirm the ability to use induction for his heating scenario, and the results he could expect.
In this customer scenario, a cable manufacturer was looking to preheat a carbon-based wire of 0.105″ (0.27 cm) diameter, before feeding it into a cable coiling machine. The machine then winds the wire into a 0.375″ (0.95 cm) diameter spring. Their current process includes using a 6ft (1.83 m) long furnace, where the wire passes at speed of 14ft (4.27 m) per minute.
The goal of this test induction heating application was to evaluate the induction heating parameters required for the customer scenario by heating the coiled wire and then making conclusions for the non-coiled one. A successful test would also mean considerably reducing the workspace required for the heating process.
An induction heater from the UltraHeat SM series was considered most appropriate for this induction heating scenario. UltraHeat SM are compact, durable and easy-to-use 5kW induction heating systems that can be used with either a water-cooled or air-cooled remote heat station. They are loaded with safety and diagnostics features and are easy to tune to a wide range of loads and coils.
At 5 kW of power applied, the target heating temperature of 850°F (~454°C) was achieved within the very first second. The temperature was confirmed by applying a tempilaq paint onto the heated part.
This induction heating test allowed the customer to confirm the ability to use induction for his heating scenario, and the results he could expect. UltraFlex engineers recommended the use of a custom induction coil for even better efficiency.
By replacing his furnace-based preheating process with induction heating, the customer would benefit from greater time- and energy-efficiency and an optimized workspace used. He would also achieve a process that is safe both for the operator and the environment, due to the lack of open flame.
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