0102030405
China Industrial Induction Heater for Steel Bar Billet Heating - Suppliers of Rod Hot Forming Machines from Factory
Product Description
Core Functionality
High-Efficiency Heating: Rapidly heats steel billets (ø20-200mm) and rods to 1200°C within seconds for forging/hot forming.
Precision Temperature Control: PID-regulated ±10°C uniformity, suitable for carbon/alloy steel hardening and tempering.
Key Specifications
Power Range: 160-200kW (380V/50-60Hz), designed for 24/7 continuous operation.
Frequency Adjustment: Dual-mode 1-30kHz for optimized penetration depth in thin rods or thick billets.
Cooling System: Closed-loop water cooling (≥25L/min) with overheating protection.
Applications & Customization
Hot Forming: Pre-heats steel bars for upset forging, extrusion, and CNC machining.
Automotive/Machinery: Processes axles, bolts, and hydraulic components with CE/ISO-certified safety.
Modular Design: Customized coil sizes for diverse workpiece dimensions.
Application Scope
Typical Use Cases: Metalworking factories, forging plants, and automotive part suppliers
1. Steel Bar Billet Pre-Heating
Forging Preparation: Rapidly heats steel billets (ø20-200mm) to 800-1200°C for subsequent forging or extrusion processes.
Uniform Heating: Ensures temperature consistency (±10°C) for carbon/alloy steel billets, reducing internal stress.
2. Rod Hot Forming & Upset Forging
Upset Forging: Precisely heats rod ends for flange/bolt head forming in automotive and machinery parts.
Continuous Processing: Supports 24/7 operation for high-volume production of hydraulic rods and shafts.
3. Gear & Chainwheel Manufacturing
Gear Blank Heating: Heats gear blanks to optimal forging temperatures (1000-1150°C) for precision stamping.
Sprocket Hardening: Localized induction hardening of chainwheel teeth to enhance wear resistance.
4. Industrial Maintenance & Repair
Metal Joining: Heats steel bars/billets for welding or brazing in pipeline and construction applications.
Stress Relief: Post-weld heat treatment to eliminate residual stresses in critical components.
Typical Industries
Automotive (axles, gears)
Mining (conveyor chains, crusher parts)
Heavy machinery (hydraulic rods, bearings)
Note: Customizable power (15-200kW) and coil designs for diverse workpiece dimensions.
Configuration and Performance
1. Core Configuration
Power System:
• Input: 380V±10%/50-60Hz, 3-phase, compatible with industrial grids.
• Rated Power: 160-200kW (adjustable for billet/rod sizes).
• Frequency: Dual-mode 1-30kHz (auto-tuning for penetration depth).
• Input: 380V±10%/50-60Hz, 3-phase, compatible with industrial grids.
• Rated Power: 160-200kW (adjustable for billet/rod sizes).
• Frequency: Dual-mode 1-30kHz (auto-tuning for penetration depth).
Heating Coils:
• Multi-turn copper coils (ID 50-600mm), water-cooled for 24/7 operation.
• Quick-change design for flexible billet/rod processing.
• Multi-turn copper coils (ID 50-600mm), water-cooled for 24/7 operation.
• Quick-change design for flexible billet/rod processing.
Cooling System:
• Closed-loop water cooling (≥25L/min @ 0.3MPa) with overheating protection.
• Closed-loop water cooling (≥25L/min @ 0.3MPa) with overheating protection.
2. Performance Metrics
Temperature Range: 800-1250°C (PID-controlled ±10°C uniformity).
Heating Speed:
• Billets (ø100mm): 15-30 sec to 1100°C.
• Rods (ø50mm): 5-10 sec for end upset forging.
• Billets (ø100mm): 15-30 sec to 1100°C.
• Rods (ø50mm): 5-10 sec for end upset forging.
Efficiency: ≥90% energy conversion (IGBT-based inverter technology).
Duty Cycle: 100% continuous operation.
3. Automation & Control
HMI Interface: 10" touchscreen with preset programs for gears/chainwheels.
Integration: RS485/Modbus TCP for PLC/robotic arm synchronization.
Safety: CE-certified with emergency stop and overcurrent protection.
4. Material Compatibility
Steel Types: Carbon steel (C45), alloy steel (42CrMo), stainless steel.
Technical Specifications
Industrial Induction Heater for Steel Bar Billet Heating & Rod Hot Forming - Technical Specifications
1. Power & Electrical Parameters
Input Voltage: 380V±10%, 3-phase, 50/60Hz
Rated Power: 15-200kW (adjustable for different billet sizes)
Frequency Range: 1-30kHz (auto-tuning for optimal penetration depth)
Power Efficiency: ≥90% (IGBT-based inverter technology)
2. Heating Performance
Temperature Range: 800-1250°C (PID-controlled ±10°C uniformity)
Heating Speed (Billets ø100mm): 15-30 sec to 1100°C
Heating Speed (Rods ø50mm): 5-10 sec for end upset forging
Max Workpiece Size:
• Diameter: 20-600mm (custom coil designs)
• Length: Up to 6m (for continuous processing)
• Diameter: 20-600mm (custom coil designs)
• Length: Up to 6m (for continuous processing)
3. Cooling & Durability
Cooling System: Closed-loop water cooling (≥25L/min @ 0.3MPa)
Duty Cycle: 100% continuous operation
Protection: Overcurrent/overvoltage/overheating safeguards
4. Mechanical & Compliance
Coil Material: High-purity copper, water-cooled
Certifications: CE, ISO, RoHS compliant
Weight: 7.3kg (portable models) to 1200kg (industrial systems)
5. Automation & Control
Interface: 10" touchscreen with preset programs
Integration: RS485/Modbus TCP for PLC connectivity
Applications: Forging pre-heating, gear hardening, rod forming
Note: Specifications vary based on customized requirements for billet/rod dimensions.
Main Components
Frequently Asked Questions (FAQ)
What is the heating speed for steel billets and rods?
For steel billets with a diameter of ø100mm, it takes approximately 15 to 30 seconds to reach 1100°C. For steel rods with a diameter of ø50mm, it takes only 5 to 10 seconds for end upset forging.
What materials are compatible with this induction heating system?
The heater is compatible with a wide range of steel types, including carbon steel (such as C45), alloy steel (such as 42CrMo), and stainless steel.
Can the heating coils be customized for different workpiece dimensions?
Yes. The system features a modular design with customizable multi-turn copper coils ranging in inner diameter (ID) from 50mm to 600mm to match your specific workpiece sizes.
What safety certifications and protections are built into the machine?
The equipment is CE, ISO, and RoHS certified. It features built-in safety mechanisms including emergency stop, overcurrent protection, overvoltage protection, and overheating safeguards.
Does the system support automated production lines?
Yes, it is equipped with a 10" touchscreen HMI interface and supports RS485/Modbus TCP protocols for seamless integration with PLC systems and robotic arms.