COIL DESIGN
At Fairview Coil Fabrication, we believe that proper coil design is a crucial aspect of any effective induction heating system. Our team of master craftsmen will work with you to analyze your process requirements and suggest a coil design that we believe will be efficient and effective for your application. The perfect coil not only allows for easy part handling but also maximizes the efficiency of the induction heating power supply, ensuring the proper heating pattern of the parts. This customized approach provides the most efficient and effective induction coil for your manufacturing process.
Important Induction Coil Design Parameters
Coil Coupling
For maximum efficiency and heat transfer, the induction coil or inductor should be designed so that the part can be placed very close to it. The term “coupling” refers to the relative distance between the coil and the part being heated. So a short distance between the coil and part is often referred to as “tight coupling” while “loose coupling” means there is more of a gap.
Operating Frequency
The operating frequency of your induction heating process will depend largely on the specific process brazing, shrink fitting, bonding, etc. and the size and shape of the part. Generally speaking, tighter coupling is preferable for lower operating frequencies. Coupling becomes less of an issue with higher frequency induction heating processes.
Cooling Considerations
Induction heating coils commonly rely on water to regulate their temperature. It is essential to maintain proper water flow for optimal heating efficiency and to prevent copper cracking, especially when the heating cycle is brief. Overheating during longer heating cycles can cause gradual coil deformation. To mitigate the risks of overheating, one can increase water flow rate or decrease water temperature. Alternatively, additional cooling circuits can be incorporated into the system. Our team will collaborate with you to ensure that your coil design adequately addresses your process and part requirements for cooling capacity.
Design Examples
Helical Coil
Simple helical wound coil, the number of turns determined by dimensions and heating requirements.​
Multi-Position Coil
When high production requirements must be met, special coils can be designed to heat multiple parts simultaneously.
Split Helical
When the heating zone cannot be reached with a standard helical coil design.
Pancake Coil
Rows of copper tubing shaped into a round flat shape, used to heat a surface that is flat.
Square Coil
Often utilized for heating the outside of a square metal shaft or bar.
Hairpin Coil
A relatively small loop-shape coil bent to conform to a shape of a specific part.
Single Turn or Solid Coil
A round inductor with just one turn, the thickness depending on the part.
Clamshell Coil
A concave version of a pancake coil.
Channel Coil
When your induction heating system is designed to supply a steady flow of parts channel coils which allow for constant workflow.
Fork Coil
Two "tines" that effectively heat two opposite sides of a part.