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The coupling in below example is used to explain how to make
the most optimal number of turns.
In this example we start with 8 turns.
■ The next step is to connect the inductor to the generator.
■ Make sure the power of the generator is set on maximum.
Depending on the heater type this is 10kW, 22kW or 44kW.
■ Press start and let the generator run shortly.
■ Read the actual power in the display of the heater.
■ Stop the heating process.
Actual power on MF-GENERATOR-3.0.
There are several possibilities now:
1. The actual power is near the max power (10kW, 22kW or
44kW) number of turns are optimal.
2. The actual power is much lower than the max power e.g. only
15kW most likely the number of turns on the workpiece is
too high, remove one turn and check the actual power again
in the display.
■ If the actual power has increased than indeed the number
of turns was too high. Repeat these steps till actual power
is approximately the max power of the generator.
■ If the actual power has decreased, then the number of turns
was already too low and became even lower. Generator is
automatically limiting power in this case because otherwise
currents in inductor become too high. Put extra turns on the
workpiece till actual power is approximately the max power
of the generator.
■ To heat a piece more evenly the turns can/must be
spread over the work piece. Leaving space between turns
is therefore allowed. This might be of influence of the
power so it might be necessary to ad or remove a winding
according above steps.
Schaeffler Technologies
Keep in mind that heat is generated directly at or underneath the
inductor cable. This, together with shape and construction of the
workpiece might be of influence on where and how fast heat in
the workpiece is generated.
A thinner part of the workpiece will heat much faster than a
thicker part.
When the inductor cable is wrapped directly over a foreign part of
the workpiece such as bolts, nuts or metal nametags this might
cause that these parts also will be heated much faster than the
rest of the workpiece. This can lead to damage of the inductor.
Avoid such situations as much as possible.
In the example below for instance the red area will heat much
faster than the rest of the coupling because there is less mass.
It is best to put temperature probe in this area (in the immediate
vicinity of a turn/winding) to avoid damage of the inductor.
IMPORTANT!
When using a flexible inductor, always put the
temperature sensor in the immediate vicinity of a
turn / winding. This is where the heat is developed
in the workpiece first. Above that keep in mind
that thinner parts of a workpiece heat much
faster so this is also a criteria where the magnetic
temperature sensor should be put.
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