SIMULATION BASED OPTIMISATION OF INDUCTION HEATING PROCESSES AND COMPONENTS
In most areas where there are multi-physical phenomena (in the case of induction heating electro-magnetic, thermal, and sometimes even fluid dynamics), numerical simulation has become indispensable. Simulation software is an important tool, especially if a coil geometry is complex. Simulations can save time, costs, energy, and resources.
For example, in coil manufacturing, there are oftentimes multiple restrictions in terms of temperature distribution in the workpiece, geometry of the induction coil and desired resonant frequency to match with the circuit of the induction generator. This leads to many coil candidates, and it would be very time consuming and costly to build and test them all. The accuracy of simulations even allow virtual coil design.
Thanks to additive manufacturing (for example SLM – selective laser melting) there are less restrictions, and the theoretically best coil geometry can be built – again and again, with the same quality (and high reproducibility).
Furthermore, the visualization of fields such as current distribution, magnetic field and of course the temperature distribution in the workpiece strengthens the understanding of the underlying physics and leads to higher product quality.
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Rough estimation of needed generator power based on heating time, workpiece material, desired temperature distribution etc.
Optimisation of induction coil cooling, to increase lifetime.
optimal induction coil geometry under consideration of desired temperature
distribution, workpiece material, frequency and other application specific restrictions.