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Induction Heatingor the
Fastener Industry
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Introducing a Faster,Better Heating
Solution
To improve production rates and astener quality,astener manuacturers use heat in their heading, thread-ing and patching production processes. With inductionheating, asteners are heated quickly, eciently, and withmaximum repeatability. The eatures and benets oinduction heating include:
A rapid heating method for improved productivityand higher volumes
Precise, even heating of all, or part, of the fastener A clean, non-contact method of heating
Safe and reliable; instant on, instant off heating
Cost effective, reduces energy consumptioncompared to other heating methods
Easy to integrate with remote workheads
Why Ambrell Induction Heating?
Ambrell has over 25 years o expertise and has installedmore than 10,000 systems in over 50 countries or manydierent induction heating applications. Fastener manu-acturers already use Ambrell or large (76mm OD) andsmall applications (0.5mm OD) alike. They know theycan count on Ambrell or a quick response, superiorsolutions, quality, versatile equipment and great support
ater the sale.Your applications will be tested in Ambrells ApplicationsLab at no charge to ensure you get the right solution oryour needs. Theres no better choice than induction orastener heating, and theres no better induction heatingsystem provider than Ambrell.
Time forThroughHeating
5mm diameter
25mm diameter
75mm diameter
SECONDS
0 10 25 100 150
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HeadingInduction heating is commonly used or preheating bolt and screw heads prior to orging.Induction heating oers many benets or the warm or hot heading process, including:
Consistency: direct application of heat for precise, even heating of the part
Quality: elimination of the springback effect for higher quality parts
Increased productivity: reduces need for post-production tempering and heat treating
Safe: Low pressure and minimal residual stress on parts Economical: reduces pressure on the die and extends die life
For hot heading applications, parts are typically heated to1,100 C, small parts (6mm diameter) are heated in justa ew seconds, but larger parts (76mm) will take longeror heat to travel to the center. Typically, asteners up to20mm in diameter will be heated inline with a headingpress with cycle times o up to 10 seconds. Fasteners withlarger diameters are heated in a multi-position coil thatproduces one part every 15 to 20 seconds or the
heading press.Ambrell provides an extensive line o induction heatingsystems or the astener industry and the heating pro-cess experience you need or high volumes o consistent,reliable parts. Our systems will heat to the center o yourastener head in a ast, energy ecient manner.
nSteel
nStainless
nTitanium
nWaspaloy
nInconnel
Required temperature for hot heading fasteners of different materials.
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Thread PatchingInduction heating is ideal or curing the paint or powder material used inthread patching. Ambrell products can greatly improve thread patchingproductivity by rapidly heating asteners up to 300 C or fowing the paintor powder coating. Benets o using induction heating or thread patchinginclude:
Quality curing: provides a superior re-ow of powder coatings tofastener threads
Precision heating: localized heat directed only to the area thatneeds heating
Controllable: adjust to precise fastener temperatures, no uneven heating
Economical: no lengthy warm up or cool down cycles
Productive: fast heating leads to improved production rates andhigher yields
Quality parts: can be individually monitored for quality
Typical induction heating systems or patching lines consist o a shortchannel coil (460mm long) or preheating the astener prior to patchingand a longer channel coil (4300mm long) or fowing the powder aterspraying. When compared to other heating methods, such as oven or IRheating, induction heating heats rom the inside out, which enables anyoutgassing o the patching material.
Many fastener manufacturersalready use Ambrell induction
heating systems for their patch-ing lines and process fasteners
as small as 0.5mm OD up to25mm OD, with process rates
as high as 81,000 parts perhour for 10mm OD
STEEL 3mm 10mm 25mm
Power(kW)
10 30-60 50-100
Through-put
36,000/hour
81,000/hour
18,000/hour
MinimumFrequency
(kHz)>10 >1.5 >1.5
Chart showing practicalinduction frequency andpower requirements forpatching applicationsfor steel fasteners.
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Committed to Your BusinessAt Ambrell, we understand that rom the smallest parts to the largestparts, your success depends on our success. And, our success ismeasured in our product quality, innovation, and exceptional customerservice. When you choose Ambrell or your astener application youwill get:
A team of induction heating experts that will work with yourorganization to understand your unique astener requirements
Application feasibility tests, in our labs, to determine the optimal
equipment range and settings or your applications Expert experience combined with science and engineering to design
the most ecient coil congurations
Coil fabrication and testing conducted in our labs
A system solution designed, built and tested at our factory in theUnited States
Worldwide support through Ambrell companies in the USA, Europe,the United Kingdom, and Ambrell distributors
Te Ambrell Advantage
Ambrell stands by a rm commitmento provide an induction heatingsolution to your business along withservice and support that goes wellbeyond the sale. The service depart-ment is always on-call for preventativmaintenance and timely emergencysupport. Ambrell will be there tomaintain operational excellence and
be sure our solution continues to meyour needs now and in the future.With Ambrell, youll get timelysupport before and after the sale.
EASYHEAT
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Ambrell Induction Heating Systems at a GlanceWith an extensive product line o induction heating systems,Ambrell has the best solution or your astener application.Our EASYHEAT systems oer requencies ranging rom150 kHz to 400 kHz and power ranging rom 1.2 kW to10 kW and our EKOHEAT systems are available inrequencies ranging rom 1 kHz to 150 kHz and powerranging rom 10 kW to 800 kW.
For hot heading and thread rolling applications, the
EKOHEAT systems are oten the perect t. Theyrepowerul, and deliver lower requencies, making them idealor through heating.
When it comes to thread patching, the best Ambrell systemchoice depends on the material and part size. A smallstainless steel astener (3mm) will require an EASYHEATsystem, while a large steel astener (25mm) requires anEKOHEAT system.
Systems include:
Ambrell workhead technology allowing
dierent parts to be processed without
a system change-over
Ease of integration into production
processes with a portable workhead
up to 30m in some systems
Wider frequency ranges allowing heating
more fasteners with dierent specica-
tions with the same power supply
Multiple capacitor and tap transformer
congurations for a more versatile
system than the competition
Agile frequency tuning for accurate,
repeatable fastener heating
Ecient power conversion minimizes
energy expenses
Expert coil designs that maximize power
delivery and save production time
User-friendly operator interface in ve
languages (EN, ES, FR, DE, IT)
CE marked and manufactured in an
ISO 9001:2008 certied facility
Small or large, Ambrell can build a systemthat will meet your fastener application
needs and exceed your expectations.
EKOHEAT
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As a pioneer in solid-state induction heating technology,with a 25-year history o innovation, Ambrell providesindustry-leading heating solutions. Our equipment,installed in over 50 countries, is supported by our networko dedicated induction-heating experts. With a rm
commitment to innovation and continuous improvement,we are proud to deliver quality products and solutions ora variety o industries and markets. Ambrell is the parentbrand to Ameritherm, Inc, Ambrell Ltd., Ambrell Sarland Ambrell B.V.
Ambrell/Ameritherm Inc. | Corporate39 Main Street, Scottsville, NY 14546
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About Ambrell
http://fasteners.ambrell.com
411-0128-10