induction coil design, fabrication, anda repair

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induction coils

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Induction Heating Coils

The Importance Of The Induction Coil

Coil design is one of the most important aspects of an induction system. A well-designed coil provides easy part handling, maintains the proper heating pattern and maximizes the efficiency of the induction heating power supply.

Induction coils are normally made of copper tubing - an extremely good conductor of heat and electricity - with internal diameters ranging from under 0.10" to over 5'. Coils are cold to the touch because they are cooled by circulating water, and are most often custom-made to fit the shape and size of the part to be heated. So coils can have single or multiple turns; have a helical, round or square shape; or be designed as internal (part inside coil) or external (part adjacent to coil).

Types of Induction coils

We will work with you to design and fabricate a coil that deliver maximum heating efficiency for your part and process requirements. Visit our coil gallery to get an idea of the wide range of coil designs we have worked with. Induction coils are produced in a wide range of shapes and sizes – they can have single or multiple turns, have a helical, round, or square shape, and be designed as internal (part inside the coil) or external (part outside the coil). We will work with you to design and fabricate a coil that deliver maximum heating efficiency for your part and process requirements.

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

Almost all induction heating coils are coiled with water flowing through the copper. For maximum heating efficiency it is critical to have maximum water flow. Overheating can cause the copper to crack, especially in processes with a relatively short heating cycle. A more gradual coil deformation due to overheating can occur with longer heating cycles.

To remedy overheating, the water flow rate can be increased and/or the water temperature can be lowered. Alternatively, additional cooling circuits can be introducted elsewhere in the system. We'll work with you to make sure your coil design incorporates sufficient cooling capacity for your process and part requirements.

custom coil #12
single position helical induction heating coil
pancake coil design
square induction coil