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Induction Heating in the Powertrain Industry
This document discusses induction heating in the automotive powertrain industry. It outlines the advantages of induction heating, its current applications, and need for continued advancement. Specifically, it calls for cooperative efforts to improve induction heating education and develop shared resources like material property databases and simulation tools to help design better induction coils and processes.
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Induction Heating in the Powertrain Industry
- 1. Induction Heating inthe Powertrain Industry Valentin Nemkov, Robert Ruffini, Robert Goldstein Centre for Induction Technology, Inc. Chester Grant, Shekhar Wakade GM Powertrain
- 2. Overview • Advantages ofInduction Heating • Status of Induction Heating in the Powertrain Industry • Advancements in the Induction Technique • Education in Induction Heating • Need for Cooperative Efforts
- 3. Advantages of InductionHeating • Short Heating Cycles and High Production Rates • Better Metallurgical Results • Good Control and High Repeatability • Small Surface Oxidation and Decarburization • Low Distortion • Favorable to the Industrial Environment
- 4. Status of InductionHeating • Widely Used in Powertrain Industry • Relatively Old Equipment and Technology • Relatively Short Coil Lifetimes • Depletion of Experienced People • Demand for Improved Induction Technique
- 5. Major Applications ofInduction Heating • Surface Heat Treating – Hardening – Tempering • Sintering • Shrink Fitting • Forging and Forming • Brazing
- 6. Demand for ImprovedInduction Technique • Existing Equipment is Relatively Old • Tighter Product Requirements • Faster “Time to Market” • Continuously Changing Requirements • Tougher Environmental Standards
- 7. Advancements in InductionTechnique • DFIH Strategy • Power Supplies and Control Systems • Computer Simulation Tools • Induction Heating Coils • New and Emerging Technologies
- 8. DFIH Strategy • Material Selection • Part Geometry • Heat Treatment Specification • Sequence of Operations • Material Handling Equipment
- 9. Power Supplies andControls • Solid State Power Supplies • Small Size and Weight • Higher Efficiency • Greater Adaptability and Controllability • Faster Response Times • Intelligent Control Systems • Process Monitoring and Recording
- 10. 2-25 kW HFPower Supply
- 11. Dual Spindle CamshaftHardening Machine
- 12. 50 kW PowerSupply with Portable Transformer
- 13. Benefits of ComputerSimulation • Faster Process Development • Accurate Results • Demonstration of the Entire Dynamics of the Process • Leaves Records for Future Study • Improves Knowledge Base • “Human Factor”
- 14. Computer Simulation Uses • Education and Self-Education • Research and Development • Case Studies • Process and Equipment Design • Advertisements and Business Presentations – See more about software on www.induction.org
- 15. Computer Simulation Strategy 3D 2D, Electromagnetic + Thermal 2D, Electromagnetic or Thermal 1D, Electromagnetic + Thermal Rule of Pyramid for Induction Heating Computer Simulation
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- 17. Time vs. TemperatureGraphs for the Scanning Process
- 18. Axle Fillet Geometry Fluxtrol Concentrator Coil Copper A Water Passage B Axle Flange
- 19. Temperature Profile and AustenitizedZone, 3 kHz
- 20. 1/4 of aHeat Exchanger Brazing Coil
- 21. 3-D Induction Brazing Simulation
- 22. Induction Heating Coils • Better Coil and Process Efficiency • More Precise Heat Pattern Control • New Materials for Magnetic Flux Control • Longer Coil Lifetimes • Coil Manufacturing Technology • Computer Assisted Design
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- 27. Status of Educationin the Induction Technique • No University Curriculum • Mainly Self Education • In-Plant Training • Generic Induction Heating Seminars • Emerging New Opportunities
- 28. New Opportunities forEducation • Computer Simulation and Educational Tools • Modern Courses and Course Books • Remote Education via Internet • International Networking
- 29. Industry Collaboration • GroupDevelopment of Basic Technologies • Development of System for Education • Development of Teaching Tools • Development of Focused Computer Simulation Programs • Development of Material Property Database for Induction Heating
- 30. Conclusions • Induction HeatingIs Not Being Used to It’s Full Potential • Many Old Processes and Equipment are Obsolete • Induction Personnel Require Education and Knowledge Updating • Cooperative Efforts are Required in: – Education – Material Property Database – Improved Induction Coil and Process Design