Industrial Chillers for Induction Heating Systems

Induction heating systems have proven to be an excellent method for working with a wide range of electrically conductive materials – these include steel, copper, aluminum, brass, plus other semi-conductive compounds such as silicon carbide and many others.

It’s a very versatile methodology, used in many industries, applications, and manufacturing processes, including:

• Automotive
• Aviation
• Marine
• Railroad
• Petrochemical – oil and gas refining
• Pharmaceutical and medical applications
• Tool manufacturing
• Packaging applications
• Electro-technical and power plant uses

Induction heating systems are used in a wide variety of ways – some common applications include:

• Brazing, tempering, and hardening of materials
• Shrink fitting
• Pre-heating of materials
• Straightening via induction heating
• Smelting processes

Advantages of Induction Heating

The three most commonly listed advantages of induction heating include the fact that it is a non-contact method for heating these types of materials; the induction process happens via AC line current converted to a higher frequency alternating current; it is a precise method, particularly important when strict temperature control is necessary to achieve the desired result – this is chiller systems become vital to the process (more on this later); the process is repeatable – predictable results are achievable consistently.

How Induction Heating Works

The material to be heated is placed in an electrical field.  The resulting eddy currents produced by the material in the field produce friction which in turn creates heat – the fine control of the electricity results in a precise, non-contact, clean rise in temperature so that the material reaches the exact desired state required in the application. It is also a much more efficient process when compared to alternatives such as flame-driven processes. Few other types of heating systems can achieve both the precision and efficiency of induction heating.

Industrial Chillers for Use in Induction Heating Systems

Industrial water chillers play a vital role in induction heating processes.  This harkens back to the fact that strict temperature control is necessary throughout most of these types of processes.  During the induction heating process, heat loads as high as 500-600C are often generated.  In order to remove excess heat being generated through induction, chilled water is used to circulate through the heating coil.  Left unaddressed, too much-generated heat would result in the potential for inaccuracies in the desired outcome, as well as interruptions to the heating process, and drastic reductions in efficiency.

Specifics Regarding AMC Series Air Cooled Chiller Systems

AMCON works closely with induction heating system providers, with the use of our air cooled chillers.  Specifically, our AMC030AC-B-1 to AMC080AC-B-1 are widely used with induction heaters from 11 kVA to 43 kVA.

In the above noted models of AMC air-cooled chillers, the built-in chilled water pump in our AMC chillers circulates 7 degree Celsius chilled water at a pressure of approximately 4 to 5 bar to the heating coil, providing quick and efficient removal of the heat generated by the induction process.  

Critical in these types of applications is the fact that the timing for heat removal is typically between two to three minutes.  This requires that the chiller selected for the process must be both very efficient and reliable, in order to maintain the operation without interruption, and ensure it is repeatable and consistent.  All these factors weigh heavily on the overall efficiency of whatever application the chiller is supporting.  Our AMC Series has proven itself in this regard – it’s why so many of our customers automatically couple our chillers into their systems, as a complete solution.  We are proud that our chillers so effectively take any guesswork out of a process or application, that they are specified as part of a complete solution to the end user.

Brazing and Welding Processes Employing Induction Heating

We have witnessed over the last several years an increase in the popularity of induction heating systems in brazing and welding processes.  Like many of the other industrial applications noted earlier, these industries have recognized the advantages of heat induction for their processes, which result in shortened cycle times for brazing and welding, along with a better end result.  Our AMC030AC-B-1 to AMC080AC-B-1 of chillers have likewise been adopted by many customers for their specific applications.  As with many other industries, brazing and welding processes now couple induction heating with our line of chillers to ensure continuous quality and reliability from start to finish of whatever specific job they are supporting.

Safety Should Be Paramount in Any Process Involving High Heat

We strongly believe that above all else, safety must be uppermost in everyone’s mind, in any industrial pursuit.  Any process or application involving high heat or high temperatures must be mindful of the inherent safety risks involved with this type of work.  This is one more reason why induction heating has emerged as a vital option in so many industrial applications.  It has proven to be not just reliable and consistent – the high control afforded by the process also makes it safer than many alternatives, such as flame-driven heating or direct firing of materials.  Our AMC chiller systems, likewise, play an important role in maintaining not just the quality and reliability of induction heating industrial processes, but also in ensuring their overall safety of them.  We work closely with all of our clients to ensure their processes are as safe as they can possibly be.

AMCON Chillers – Here to Help Induction Heating Processes

We hope you have found this summary of how our chiller systems fit into induction heating processes and applications.  We welcome your comments and questions.  Contact our team today.