UltraFlex induction heaters used to increase the efficiency of an induction-based bonding process

RONKONKOMA, N.Y. - Nov. 18, 2022 - PRLog -- The efficiency of UltraFlex induction heating solutions compared to other induction heaters had been showcased in a test application recently set up for an UltraFlex customer. The customer - an experienced manufacturer from the Appliances and HVAC industry - was looking to replace his old induction heating equipment, pursuing increased efficiency and higher productivity.

In this application test a steel detail of very big size - 114.75 (OD) x 50 (ID) mm - had to be bonded to a non-conductive ring with dimension 105.3 (OD) x 92.3 (ID) mm and 2.15 mm in thickness. The steel part had to be heated so that the adhesive could be cured and a gasket bonded to the steel part.

The customer's requirement was for a maximum heating time of 20 seconds, maximum heating temperature of 200°C and ability to use the induction bonding process on the production line. He also had an existing induction coil which he asked to be re-used in the process.

Being a leading manufacturer of advanced, digitally-controlled induction heaters, UltraFlex set up an application test aiming at evaluating the efficiency of UltraFlex induction heaters for the customer's bonding scenario, considering all requirements given. The UltraFlex induction heater considered most appropriate for this application case was an induction system from the UltraFlex UltraHeat SM series. UltraHeat SM are compact and easy-to-use 5kW induction heating systems that can be used with either a water-cooled or air-cooled remote heat station. They feature an advanced induction heating power supply utilizing the latest switching power technology.

To ensure that no overheating of the part would take place, tempilaq paint was used to detect when the temperature of 204°C had been reached.

UltraFlex engineers successfully connected the customer's induction coil to the selected UltraFlex induction heating system. At a power output of 4 kW, it took 12 seconds to successfully heat the steel detail. Follow-up evaluations, however, showed that the induction coil provided by the customer was working at 50% efficiency only and replacing it with a custom induction coil would allow for significant time- and energy-optimization of the bonding process.

This test application showed that by using an UltraFlex induction heater, along with a custom-designed coil, the customer could achieve much improved energy- and cost-efficiency for his induction bonding process, as well as higher-quality bonding results. He could also successfully transfer the induction-bonding process on the production line, and ensure even higher productivity. Finally, thanks to the lack of open flame and noxious emissions, this induction bonding process would be completely green and safe - safe for the operator, safe for the environment.

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ultraflexpower.com