Induction Heaters
Induction heaters
An induction heater is a device used for heating metals, especially those that are more significantly affected by a magnetic field, such as iron, steel, brass, etc. It operates by utilizing electric current (electricity) and inducing a magnetic field in metal parts to achieve its effects.
The application of frequency bearing heaters is for heating purposes to enlarge assembly components in various industries. By heating, the diameter and size of components increase, making it easier to assemble parts together using a rapid heating method. This allows components to be heated quickly over a short period, facilitating easier assembly (or disassembly) after their size has increased.
Due to the air gap between components, the dimensional changes vary since the air gap leads to differences in the amount of induced heat, resulting in a significant temperature difference between two parts.
Induction heaters are particularly useful for removing and fitting (assembly and disassembly) press-fit components, such as various bearings.
Induction heaters have various applications in industries, including disassembly and assembly, installation, and replacement of sensitive parts with press fit tolerances, such as different types of bearings, gears, couplings, bushings, and various rings from shafts and housings.
Additionally, this equipment is commonly referred to in industries as an induction bearing heater.
Established brands of frequency induction heaters
Among the notable brands used worldwide are SKF and FAG, along with certain German and Chinese brands, each holding a position in the global market. However, in Iran, their credibility has diminished due to the lack of after-sales service and warranty. If these products fail, they become unusable and ineffective. Given the domestic production capabilities of this product, the price and purchase cost of imported ones are significantly higher, sometimes even several times more. Considering the dollar prices of this equipment and the stark difference between domestic prices and foreign import costs, as well as the absence of any warranty for foreign products, the one-year warranty and five-year service provided for Matsou’s induction heaters or bearing warmers make their products more economical.
SKF Bearing Heater Model EAZ and Similar
The EAZ models, or fixed coil models, are among the most commonly used frequency induction heaters in the SKF brand, recognized more in Iran. They are specifically designed for the assembly of various types of inner rings of cylindrical bearings or roller bearings on shafts. Typically, before mounting the rings onto the shafts, they are heated using this device. Once expanded, they are placed on the shaft and, after cooling, set firmly in place, remaining in a press-fit condition. With the arrival of flexible coil models and their reduced consumption, the EAZ model has almost lost its application. However, the technical engineering company Mana Tejarat Soroush, with sufficient experience in bearings and auxiliary equipment, is capable of producing various induction heaters specifically for heating and warming bearings.
SKF Bearing Heater Model TIH and Similar
The TIH is another model of frequency induction heater by SKF, featuring a yoke or collar and categorized as a fixed coil. Models like TIH-100 and TIH-030 have been released. This model is among the most widely used in industries by both SKF and similar companies, allowing the bearing to be mounted on the shaft after heating to a specific temperature and expanding it.
Various models of bearing heaters from different brands available at this company can be repaired, refurbished, and redesigned. Therefore, prior coordination is necessary for further assessment of the bearing heaters sent in for restoration.
Below is a sample of models manufactured by this company that are fixed coil or stationary coil types, which are dimensionally and operationally similar to the TIH-030 model from SKF.
Applications
Bearing heaters are most commonly used for the replacement of rings and couplings. They are also used for the assembly and disassembly of spherical or conical bearing rings and cylindrical roller bearings onto shafts or housings.
The inner rings of cylindrical bearings used for roller bearings are press-fitted onto the neck of the roller, and assembly can be performed through heating followed by installation. However, disassembly is nearly impossible as heating the ring can cause damage, cracking, or breakage to both the ring and the roller. Induction heaters are utilized for this process.
Repair, Service, and Redesign of Various Induction Heaters
Other Applications of Frequency Induction Heaters
Other applications include the lubrication of solid, plastic, and rubber chemicals, as well as heating fluids in flow, including water, oil, and even specific chemicals, and of course, high-efficiency controlled heat transfer from one location to another. Additionally, heat treatment, surface hardening (hard plating) of components, especially gears and rings, and the heat treatment leading to the melting of metals (especially steels) (as in induction furnaces) are among their other applications.
Another use of these devices is the heating of components, particularly steel, to reach the melting point or red-hot state for purposes such as hardening, plating, or melting metals.
Application of Induction Heaters in Industry
Induction heaters, which operate based on the principle of electromagnetic induction, have extensive applications across various industries. These devices create heat within a metallic object by generating a changing magnetic field without the need for direct contact between the heat source and the object. This process offers high efficiency, excellent heating precision, and controllable heating conditions. Below are some of the primary applications of induction heaters in the industry:
Processing and Production of Metals
- Pre-Processing Heating: Induction heaters are used to heat metals before processes such as rolling, bending, and forging.
- Heat Treatment: Processes like hardening, annealing, and stress relieving can be performed using induction heaters.
- Soldering and Welding: Induction heaters are utilized to heat metals for soldering and welding with precision and without contact.
Medical
Manufacturing Medical Equipment: Induction heaters may be employed in the production of certain medical devices, such as surgical instruments and implants, for specific processes like welding or heat treatment.
Petrochemicals and Refining
Heating of Tanks and Pipes: Induction heaters are applied to heat chemicals, oil, and gas in tanks or during transportation through pipes to prevent the freezing of materials and ensure smooth flow.
Food Production and Processing
Sterilization Processes: Induction heaters can be used to sterilize packaging and food products.
Heating and Cooking: In some cases, induction heaters are used for heating or cooking food, offering advantages such as precise temperature control and improved product quality.
Automotive Manufacturing
Heat Treatment of Parts: In the automotive industry, induction heaters are utilized for heat treatment of vehicle components like crankshafts, gears, and shafts.
Advantages of Using Induction Heaters in Industry
- High Efficiency and Lower Energy Consumption: Due to the induction mechanism, induction heaters operate with high efficiency and low energy usage.
- Precise Temperature Control: There is the capability for precise temperature control in heating processes.
- Rapid Heating: Induction heating is significantly faster than traditional methods.
- Safety and Hygiene: As there is no need for flames or toxic gases, induction heaters are safer and more environmentally friendly.
Overall, induction heaters are versatile and efficient tools utilized across various industries to enhance manufacturing processes, product quality, and energy efficiency.
Replacing the inner rings of cylindrical roller bearing bearing rollers that are pressed onto the shafts of the roller mills (i.e., disassembly and assembly).
The Working Method of Induction Heaters
The operation of induction heaters is based on the principle that an electric current flowing around a metal generates a magnetic field, thereby inducing electrical currents within the metal itself. This magnetic field causes atomic agitation and internal friction, ultimately leading to internal heating that occurs from the surface in contact with the electric coil moving inward. This process produces heat primarily within the components, especially steel ones, where the heat distribution gradient moves from the surface to the interior, making it particularly effective during disassemblies. In addition to heating the components, some heat is also generated in the coil, which necessitates internal cooling for all parts, accessories, and the heating unit itself.
Among the well-known brands of induction heaters, SKF, FAG, and others are notable, although unfortunately, they do not provide after-sales service in Iran. This company addresses market needs by repairing and refurbishing various types of these heaters.
Factors Affecting Heating in Induction Heaters
The amount of electric current and the magnetic field play significant roles in generating heat through induction. Thus, we can directly associate the factors that produce heat with:
- The amount of current
- The weight, volume, size, and geometric shape of the component
- The level of impedance or resonance – the material of the parts – the number of coil turns
Calculations, Design, and Manufacturing
Our company offers services in the design, calculation, production, and buying and selling of industrial frequency induction heaters with reasonable pricing for various industrial applications, as outlined below.
Services of this Company
Repair, refurbishment, and redesign of existing induction heaters in industries, design, and production of various induction heaters, installation services, assembly, and disassembly of special parts with press fit clearance such as rings, gears, wheels, drums, rotating furnaces, spacers, couplings, inner rings of bearings, roller bearings, and various types of bearings including cylindrical roller bearings and tapered roller bearings related to rolling mills in diverse industries including aluminum, copper, steelmaking, and castings. The company also provides heating solutions for heavy parts with significant press fits of up to 1 millimeter, utilizing consulting and services offered by this company.
Moreover, the design and manufacture of devices for pre-heating parts before welding, with temperature control capabilities at various levels, as well as post-welding heating to control the cooling gradient of parts, are available for various applications including welding of pipelines for gas, oil, and water, and special industrial components such as housing for rolling mill chucks.
Design and manufacturing of induction heaters for chemical processes with temperature control, timing, specific volume, and material flow rate options.
The capability to design and manufacture heaters and furnaces for chemical reactors, with programmable features in various sizes and applications tailored to requests.
Replacement of various couplings from motor and gearbox shafts using press fitting up to 0.3 millimeters in small diameters.
Induction heaters for complex and sensitive tasks
- Design and production of induction heaters with very low power as closed-loop heaters, specifically for assembling small and large bearings and rings.
- Design and production of medium-power heaters for high-volume, uniform tasks, available as stationary coils, and of course, customizable up to sizes with a diameter of 1 meter and weights of up to 1200 kilograms for assembly and disassembly.
- Flexible heaters with power ratings ranging from 15 kilowatts to high power levels, including 100 kilowatts and above, utilizing operating frequencies from 5 to 50 kHz based on requirements, with automatic frequency adjustments and programming capabilities for repetitive tasks, as well as data display on a Human-Machine Interface (HMI), and cooling systems using internal water circulation or chillers for assembly and disassembly.
Disassembly and assembly of rings, gears, large wheels, and spacers that are press-fitted onto shafts.
Safety for personnel and equipment
Considering the working conditions of this equipment, which directly involves human factors, and given the operator’s direct interaction with the machine and the presence of a magnetic field and metallic and steel cores, there is a possibility of creating high-voltage currents in components and even in coils. Therefore, to prevent severe and possible electric shocks, all heaters from this company are equipped with personnel safety features, resulting in zero risk of electric shock. To order and purchase various induction heaters, you can use the contact section or the communication field at the bottom of the page to submit your request, so that further arrangements for additional information can be coordinated.
Application
The application of induction heaters spans various industries such as Steel, Mine, Food, Cement, Petrochemical, Gas & Oil, and other Industrial sectors, for mounting and dismounting services of components.
We utilize the best, typically European materials available, featuring portable and fixed bodies with stationary coils and flexible cables.
We provide the quickest and highest quality service for the replacement of press-fit components.
Performing services:
One of the tasks of this company is to perform parts replacement services for factories in the form of repair projects. The working method is that after the applicant’s factory sends a request to the support unit and announces the specifications and makes the necessary arrangements, an appointment is made to visit the applicant’s site, and after preliminary checks and planning, it will be possible to provide special equipment for the project.
Considering that the operation and functionality of induction devices such as furnaces, heaters, power control systems, and motor starter drives are quite similar, this company collaborates in the repair of all the aforementioned equipment and is capable of repairing, refurbishing, and enhancing various induction furnaces up to medium power.
Questions:
Can induction heaters be used to replace the rings on roller bearings?
Where can we buy induction heaters?
Where can we find the specifications and necessary information for ordering an induction heater?
Should we choose an Iranian-made induction heater or an imported one?
Do induction heaters require a warranty or guarantee?
For which machines or components can we use induction heaters?
What characteristics do heating capacity, frequency, and input current change in induction heaters?
Can induction heaters be used for assembling and disassembling steel parts such as rings, gears, or bearings from shafts or inside bearing holes?
Where can we obtain services and repairs for induction heaters from other brands like SKF and others?
Where can we purchase the Matsuko Iranian bearing heater?