Metal Soldering Induction Plants

What gives induction heating when soldering

The electromagnetic field creates heat in the metal elements of the compound. Solder melts from heated surfaces, so with a properly constructed process, you can get a repeatable temperature cycle and reduce the oxidation of the surrounding areas. The shape of the inductor determines the location and width of the heating zone, and the power and time set the speed of reaching the soldering temperature.

For serial operation, the unit can work in conjunction with the device, the mechanism for supplying parts or dosing solder. For single and different connections, LN is convenient with a remote inductor. The result depends on the gap in the connection, surface preparation, solder composition and flux, so the power of the generator alone does not determine the quality of the seam.

local and controlled heating of the connection area;

the ability to repeat the specified power and cycle time;

the use of ring, contour, connector and multi-seat inductors;

the ability to embed heating in a manual post or an automated complex.

What data is needed for selection

To calculate, a drawing or sketch of a node with the size of the soldering zone is required. It is advisable to pass samples of parts and report the actual performance: batch size, number of connections per shift or allowable time of one cycle. If the technology is already approved, the initial requirements are the process map and documentation of the customer.

brands and magnetic properties of metals;

diameter, wall thickness, mass and relative position of parts;

solder type, its melting range, flux or protective atmosphere;

required temperature, heating time and allowable overheating;

clearance, method of fixing parts and location of solder;

manual loading or work as part of the line;

available power, installation location and liquid cooling system.

How to choose a series and frequency

AVVS is used for small parts and compact areas where an increased concentration of heating is useful. ABB and AVZ are suitable for much of the soldering operations of medium parts. AVN is considered at a large mass, a significant cross-section or the need for a deeper and more uniform heating. LN is chosen when the operator needs to bring the remote inductor to a stationary or large-sized product. The final choice is made after calculating the “detail-inductor” connection and the trial cycle.

Too high a frequency can concentrate the heating on the surface, and insufficient power will increase the cycle and heat loss. Excess power without proper control can cause local overheating. Therefore, the frequency, inductor, power and time program are considered as a single technological system.

Example of an indicative calculation

An indicative example for an initial estimate. Assume that the brazing zone requires heating the equivalent of 0,5 kg of steel parts from 20 to 800 °C. With an average specific heat capacity of 0,65 kJ/(kg·°C), useful energy is 0,5 × 0,65 × 780 = 253,5 kJ. Assuming an overall process efficiency of 50 %, the system must draw approximately 507 kJ from the mains. At an average mains input power of 20 kW, the estimated time is 507 / 20 = 25 seconds.

The actual cycle may differ due to inductor geometry, electromagnetic coupling, thermal conductivity of parts, tool heating, environmental losses, and exposure to solder sputtering. The values are specified by a test with a real detail selected by the solder and ordered by the inductor.

Delivery and inspection of equipment

UralInduktor develops the concept of the post and forms a technical solution. The Chinese factory performs detailed design and manufacture of equipment. A simple inductor is usually included in the price; complex, multi-seat or replaceable inductors are calculated separately by agreement.

Before shipment, the factory checks the installation with the inductor ordered. In Miass, the equipment is rechecked without load at full connection. Management and documentation are delivered in Russian. On the territory of the customer, specialists carry out commissioning and testing on details with the registration of acts. Warranty - 18 months, the beginning of the term is determined by the contract: from the date of shipment or the signing of the commission act. Price on request.

What to send for selection

Send the connection drawing, metal grades, solder information and required performance. We will offer installation series, frequency range, preliminary power and inductor circuit. The final modes and quality of soldering are confirmed by trial tests on real parts.