1. Turn-to-Turn Arcing
Meaning
Turn-to-turn arcing means that the insulation between turns fails and a continuous arc discharge occurs under high voltage, commonly known as "sparking/arcing". Turn-to-turn arcing means that the insulation between turns fails and a continuous arc discharge occurs under high voltage, commonly known as "sparking/arcing". Mild manifestations include local sparks and current fluctuations. Severe cases may lead to insulation burn-through and turn-to-turn short circuit.
Root causes
Turn-to-turn arcing is caused by insulation damage, abnormal cooling system, environmental and conductive foreign matter, excessive medium frequency voltage, etc.
Solutions
l Check insulation regularly and reapply insulating paint/mortar.
l Remove the scale regularly, check water pressure/flow, and eliminate water leaks.
l Keep the coil clean, blow out dust regularly, and control the ambient humidity.
l Low-Power Operation: Initiate the equipment at a low power setting, ensuring the material inside the induction heating furnace does not melt.
2. Carbonization of Insulating Rods
Meaning
Carbonization of insulating rod refers to the fact that the epoxy insulating rod fixed to the induction coil has been exposed to high temperature, high pressure, arc, dust, and moisture for a long time. The surface and internal insulating materials are burned, oxidized, and cracked by high temperature, turning into a black carbonized layer, which is called insulating rod carbonization.
Root causes
The carbonization of the insulating rod is caused by long-term high-temperature baking, slight arcing between turns, attached dust and iron filings, and high voltage.
Solutions
l Clean the scale on the inner wall of the induction copper pipe to ensure that the cooling water flow and water pressure meet the standards.
l Ensure uniform spacing between turns, no deformation or extrusion of the coil, and ensure good insulation between turns.
l Keep the furnace area dust-proof and clean the coils and insulating rods from dust regularly.
3. Slow and Uneven Heating
Meaning
Slow and uneven heating means the workpiece heats up slowly, has low heating efficiency, uneven heating, and one end is hot and the other is cold.
Root causes
The slow and uneven heating is caused by the unreasonable number of coil turns and the inappropriate heating length.
Solutions
l Adjust the number of coil turns and add capacitor.
l Correct coil concentricity; standardize workpiece loading and positioning.
Only by solving the turn-to-turn arcing, carbonization of insulating rods and slow and uneven heating, can the service life of induction heating furnace be extended.