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High-Efficiency Industrial Induction Heater for Steel Bar Heating | China Suppliers & Factory for Hot Forming
Product Description
1. 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.
2. 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.
3. 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).
- Heating Coils: 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.
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.
- 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 - 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) |
| 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
What is the heating speed and temperature range of this induction heater?
The system heats ø100mm billets to 1100°C in 15-30 seconds, and ø50mm rods in 5-10 seconds. The PID-controlled temperature ranges from 800°C to 1250°C with a uniformity of ±10°C.
Can the heating coils be customized for different workpiece sizes?
Yes. The system features a modular design with quick-change, water-cooled copper coils that can be customized to accommodate workpiece diameters from 20mm to 600mm and lengths up to 6m.
What are the power specifications and frequency ranges?
The induction heater operates on a 3-phase 380V (±10%, 50/60Hz) power supply. It offers an adjustable rated power of 15-200kW and a dual-mode auto-tuning frequency of 1-30kHz to optimize penetration depth.
Does this machine support continuous industrial production?
Absolutely. It is designed for 24/7 continuous operation with a 100% duty cycle, supported by a closed-loop water cooling system (flow rate ≥25L/min @ 0.3MPa) and comprehensive protection safeguards.
How can this induction heater be integrated into an automated production line?
The heater is equipped with a 10" touchscreen HMI interface and supports RS485/Modbus TCP protocols, making it easy to synchronize with external PLCs and robotic arms for automated processing.