Induction automotive manufacturing Benefits
Meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy
Increases production rates with faster heating cycles
Reduces defect rates with repeatable, reliable heat
Eliminates variability from operator-to-operator, shift-to-shift
Maintains metallurgical characteristics of the individual metals
Induction brazing is a repeatable process that isn't as labor intensive as a flame often is. The process can heat the assembly rapidly and more energy-efficiently than a torch without the safety risks that come with an open flame
Customer's client was unhappy with the results from MIG welding, which drove them to look at induction as an alternative process. Induction heating proved to be a fast, repeatable heating method for the application...
A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75 (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer...
A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.
A four turn split helical coil is used to heat the steel assembly to 1400°F (760°C) for 85 seconds. The coil design allows for the steel fitting to expand away from the steel tube which allows braze to flow through the joint.
The steel axle was painted with temperature indicating paint and a thermocouple was attached to the part.
A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.
Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times
Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.
Even heating of the spring before dipping provides uniform flow and provides consistent thickness of the nylon coating
Heating steel rivets prior to head forming
Heat the end of lorry catalytic converter exhaust system. The assembly must be held at target temperature for 200 hours, whilst the assembly is vibrated to test the weld strength
Temperature indicating paint was applied to the parts, and it took 10 seconds to heat the various styles of the part to the targeted temperature. This testing achieved the client's time and quality objectives.
Bonding with induction heated a steel washer to the target temperature to enabling adhesive curing; it will be part of an automated process for an automotive industry application
Induction bonding enables rapid heating, can easily be integrated into the client's manufacturing process due to modest space requirements and delivers a highly repeatable process.
Filter modules are assembled on the fixture with ring gasket. Pressure is applied to the modules, modules are rotated and induction heating is started. After 10-12 seconds, heating is halted and the modules are removed from the fixture.
Heating to 500°F is accomplished through the use of the unique coil; molding is continuously processed at a rate over 20 feet per minute.
Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing
Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond
The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly
Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.
A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft.
A unique four-over-four double wound pancake coil is used for the bonding application.
Automotive manufacturers are constantly searching for cost-effective production technologies.
To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.
Heat multiple joints on solar flex circuit strips to 500°F (260°C) within ten seconds for a soldering application.
A five turn helical coil is used to heat the gear end of the shaft to 1700°F
Induction shrink-fitting is fast, presents significant energy savings over an electric oven, requires a more modest footprint than an oven and can be easily integrated into an automated process
The customer was using a torch, which can lead to inconsistent part quality. Induction's precise heating means the client can count on consistent results in their process
A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 °F (240 °C) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.
Induction heating provides more accurate control of heat vs a flame burner, it heats only the knuckle, not the whole part, it prevents discoloring due to lower temperature used and increases productivity due to repeatability & ease of operation. A foot pedal & timer is used.
To heat aluminum and steel camshaft gears to over 500°F within 4 minutes for a shrink fitting application.
To heat various sizes of aluminum auto trim to 500°F (260°C) at a rate of 30 ft. (9.1m) per minute for curing an adhesive.
To bond rubber gaskets to the top and bottom of a steel gas tank assembly.
To heat the face of an engine valve head to 900°F and maintain the temperature for an extended time, high temperature stress test.
To heat an oil suction assembly (steel tubing and filter cap) to 1,850°F (1010°C) within 15 seconds for a brazing application.
To heat threaded steel studs for insertion into a plastic tail-light assembly at 450°F.
To pre-heat the seam of a truck axle to over 300°F within 15 seconds for a welding application and maintain temperature within the welding zone
A four-turn helical concentrating coil is specially designed to deliver uniform heat to the steel seat belt retraction gear.
The c-lams are inserts for an automotive industry application. In production the robotic pick-and-place will occur for plastic overmolding after heating by induction.
The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.
The client had been using torches for preheating. However, due to process improvements thanks to new automation in their facility, torch heating became too slow. This resulted in a backlog that kept them from maximizing their throughput.
Using induction for shrink-fitting magnetic steel pistons onto a chrome shaft; the client was using an unreliable handheld induction system and wanted a higher quality induction shrink-fitting solution.
To heat steel wire embedded in rubber molding for a bonding application in the automotive industry