Induction Heating Equipment

induction annealing systems have been used for many applications including band annealing inserts, post weld annealing pipe joints, electrical connectors, bread knife ends, clock springs and seat belt springs.

Monad induction annealing systems utilize an in house range of state of the art power units featuring the latest solid state switching techniques and state of the art magnetic technologies. Induction annealing is a heat treatment in which a material is exposed to an elevated temperature for a period of time and then cooled. The aim of the process is to reduce the hardness of the metal and improve its ductility. Specifically annealing is the process of bringing the material to its softest point. Three stages of induction annealing:

• Part is placed in work coil and heated to the correct temperature. Temperature is verified by an optical pyrometer. Hold the material at the specified temperature for a given time. This can again be confirmed by the pyrometer. Monad’s system is closed loop with the generator being controlled by the pyrometer to ensure temperature stability.
• Part to be cooled slowly back to ambient temperature.
• Benefits of induction annealing systems:
• Heat is generated directly into the material.
• Energy costs reduced.
• Accurate, repeatable heat cycle.
• Controllable heat affected zone.
• Temperature accuracy.
• Reduced surface oxidation.

Induction heating equipment is also used for high-temperature vacuum or heating under an atmosphere for such processes as infiltration and treatment of composites. These materials must be subjected to long heating cycles last several days at high temperatures, up to 2,200°c at various gas and vacuum pressures. Multizone heating is often used with mf power exceeding 1000 kw.

induction bonding and curing includes the processes of joining a metal or conductive material to a rubber or plastic material with or without a third bonding agent. Induction bonding requires accurate heat control while still reaching temperatures that cause bonds to form. monad offer control of the process through optical pyrometry ensuring repeatability and reduced waste. we can also integrate into both in line and cell type production environments as our systems have rapid and accurate heat cycles.

induction heating is widely used for brazing applications. The reason for its popularity is heat can be applied to the surface and the filler material very precisely. By having the capability of applying heat  to a precise area the overall processing time is reduced significantly form what is experienced with a furnace or direct flame heating. Oxidation along with structural or chemical changes in the treated parts is reduced to a minimum. Substantial savings in energy costs are realized for medium and large production rates. power requirements are generally low, e. G. : from 10 to 100 kw. Our portable transistorized power supplies are ideal for many brazing applications. Various types of inductors can be used such as, external, internal multi-turn, pancake, hairpin, proximity inductors, etc.

Induction hardening technology systems have been used for many years in the automotive, aerospace and general engineering components industries. However by using the latest solid state switching techniques and state of the art magnetic technologies in conjunction with our advance matching system we are often able to reduce input power requirements for a given process over more traditional methods, leading to installation and running cost savings.

Induction hardening technology is utilised as a method of locally heating the surface of a carbon steel by an alternating electric current. It is usually necessary to rapidly cool, or quench the heated volume to form martensite, the desired hard microstructure.

Monad have designed and manufactured many induction hardening technology units for the hardening of steels. Products that have been hardened include axle shafts, ball joints, camshafts, flanges, gears, half shafts, steering racks, track rod ends transmission components valve barrels, valve seats and wheel hubs.

semi-solid forming consists of injecting a metal under high pressure, which has been heated until it attains a semi-solid/semi-liquid state. This process has the following advantages:

elimination of porosity in molded parts that is turbulence is eliminated.

adaptable to all types of injection molding machines.

transfer of ingots in a horizontal position without distortion and material wastage.

energy savings, since it is sufficient to heat instead of melting.

rapid heating.

We are able to offer a range of standard and bespoke induction shrink fitting systems for a whole range of traditional and non traditional components. These highly cost efficient ‘induction heating systems’ are based on the very latest induction heating technology. Designed and manufactured entirely at our modern manufacturing facility. Our approach is unique as all aspects of the project including design, manufacture, machining, hmi and embedded programming is handled internally. induction shrink fitting is a procedure in which heat is used to produce a very strong joint between two pieces of metal, one of which is inserted into the other. Heat is applied to one of the pieces so that it expands, the other component is at ambient temperature. At this point the two pieces are placed one inside the other. As the hot component cools it contracts onto the already cool component producing interference and pressure which holds the two pieces together mechanically.

Monad have Designed Induction Soldering & Brazing machines into several industry sectors including automotive, aviation, liquid gas and white goods. Materials brazed include, aluminium, brass, copper, alloys, iron and stainless steel.

Monad Brazing & Soldering systems have a variety of options available. Multiple head systems allow different parts to be brazed within the same production time. These are fully Embedded programmable and can be operated by a part number system which will select the relevant parameters automatically.

surface treatment refers to various heating operations such as the following:

• Degreasing, pickling & drying
• Galvanizing & tinning
• Curing of paints, varnishes & plastification
• Annealing
• Plating
• This heating technique realizes the following benefits:
• Better adherence to the substance applied to the metal
• Higher quality surface appearance
• Excellent reproducibility which is important when drying colored materials
• Highly flexible operation by means of easy selection of processing temperatures
• Compact and instant heat on off capability controls thermal pollution in the working environment

One of the main induction heating equipment for welding is for producing tubes and other closed profiles made of steel, aluminum or copper. Some advantages of the induction heating equipment used for this process are high production rates, quality, regularity of the weld, welding strips without first pickling, and lower power consumption.

Induction forging technology is a method of plastically deforming a metal accomplished by hammering on a single piece of metal. materials processed include aluminium, brass, copper, steel and stainless steel. Monad built feeders having a variety of handling solutions including pinch wheel, pusher, walking beam and caterpillar type drive units. The above systems are all embedded controlled and have the ability to monitor or control any parameter requested. Inductelec bar end heaters utilize a variety inductor designs depending upon the associated handling system in the unit. Typical concepts include conveyors, pick and place, v block, rotary table and pneumatic cylinder pusher systems. All the above systems can be tailored to customers exact requirements. The industry norm is to have a standard unit which does not allow flexibility or the customer to integrate features that would benefit their specific process. Monad believe in consultation as no two applications or customers are identical. We manufacture systems bespoke allowing input from the customer and providing the optimum solution for your particular process.

• Both mf and rf power units are available
• Handling systems suitable for both billet heating and bar end heating
• Repeatable, controllable heat
• Reduced energy costs
• Less oxidation of component improving tool life

A crucible furnace consists essentially of a water cooled induction heating coil would around a refractory lining made of a ramming material mixture which forms a crucible that holds the molten metal. this type of melting furnace is used primarily in steel and iron foundries, however they are also used for melting nonferrous metals.

MONAD are able to offer a range of standard and bespoke Induction Heating Systems for processing a whole range of traditional and non traditional components. These highly cost efficient ‘Induction Heating. Systems’ are based on the very latest Induction Heating technology. Designed and manufactured entirely at our modern factory, our approach is unique as all aspects of the project including design, manufacture, machining and Embedded controlling is handled internally.

Induction heating systems have been used for Induction Hardening, Induction Melting, Induction Casting, Induction Annealing, Induction Forging, Induction Brazing & Soldering.

MONAD Induction Heating Systems utilize an in house range of state of the art power units featuring the latest solid state switching techniques and state of the art magnetic technologies including impedance matching and high efficiency work heads. Importantly all systems can be offered with low impedance output circuits to enable hand loading of components and exposed coils without the risk of electric shock or RF burns.

However any advantages gained by our power unit technology could potentially go untapped if it is not coupled with a suitably efficient and reliable system for the parts handling or accurate jigging and tooling.

Monad are able to offer a range of standard and bespoke Induction Bending systems with a wide range of traditional and non traditional components. These highly cost efficient ‘Induction bending’ are based on the very latest Induction Heating Technology. Designed and manufactured entirely at our modern manufacturing facility, our approach is unique as all aspects of the project including design,manufacture, Machining and Embedded Automation is handled internally.

Induction bending systems have been used for bending in a host of industries including the fork lift fork and tube bending sectors. Monad Induction Bending systems are in daily use across the globe carrying

out all manner of induction bending processes including:

• Railway Clips

• Tube Bending

• Forklift Forks

• Leaf Springs

• Clock Spring Ends

• Anti-roll Bars

MONAD have many mini melt Induction Melting systems operating in industry. The materials that have been processed include gold, silver, platinum stainless steel and brass. The system is used by many scrap metal dealers for analysing the content of large loads bought in. A representative sample is melted and spectrometer analysis gives the percentage content of each material type.

A crucible furnace consists essentially of a water cooled induction heating coil would around a

refractory lining made of a ramming material mixture which forms a crucible that holds the

molten metal. this type of melting furnace is used primarily in steel and iron foundries, however

they are also used for melting nonferrous metals.