Abstract: An induction heating system includes a power source and an induction head. The converter output is at a voltage that is not greater than the voltage applied to the coil. The induction head includes a housing that houses a conductive coil disposed to induce heat in a workpiece and the coil is wound to be tuned to the output power. The coil is wound in a stacked spiral pattern with at least two turns in each layer. A flux concentrator is disposed about the coil with a potting compound around the concentrator and coil. Spacers maintain a desired separation between the head and the workpiece. The coil is a tube carrying a coolant. The head includes a wear surface that prevents contact of the coil and the workpiece, and a thermal insulator between the coil and wear surface. A non-contact temperature sensor is mounted to the housing.

Abstract: An induction heating system includes a power source and an induction head. The converter output is at a voltage that is not greater than the voltage applied to the coil. The induction head includes a housing that houses a conductive coil disposed to induce heat in a workpiece and the coil is wound to be tuned to the output power. The coil is wound in a stacked spiral pattern with at least two turns in each layer. A flux concentrator is disposed about the coil with a potting compound around the concentrator and coil. Spacers maintain a desired separation between the head and the workpiece. The coil is a tube carrying a coolant. The head includes a wear surface that prevents contact of the coil and the workpiece, and a thermal insulator between the coil and wear surface. A non-contact temperature sensor is mounted to the housing.

Abstract: An induction heating system includes a power source and an induction head. The converter output is at a voltage that is not greater than the voltage applied to the coil. The induction head includes a housing that houses a conductive coil disposed to induce heat in a workpiece and the coil is wound to be tuned to the output power. The coil is wound in a stacked spiral pattern with at least two turns in each layer. A flux concentrator is disposed about the coil with a potting compound around the concentrator and coil. Spacers maintain a desired separation between the head and the workpiece. The coil is a tube carrying a coolant. The head includes a wear surface that prevents contact of the coil and the workpiece, and a thermal insulator between the coil and wear surface. A non-contact temperature sensor is mounted to the housing.

Abstract: In one exemplary embodiment, the induction heating system includes an induction heating power source. The induction heating power source is operable to identify an induction heating device coupled to the induction heating power source. The exemplary induction heating power source is operable to automatically limit power based on the identity of the induction heating device.

Abstract: A method and apparatus for heating a workpiece. An induction heating system is used to induce magnetic fields in a workpiece to inductively heat the workpiece. The induction heating system may comprise a portable power source, a portable power source controller, a fluid-cooled induction heating cable, and a portable cooling unit. The induction heating system may be used to perform a variety of induction heating operations, including: annealing, surface hardening, heat treating, stress-relieving, curing, shrink-fitting, etc.

Abstract: A system and method for inductively heating a work piece. The induction heating system is coupleable to a plurality of temperature feedback devices operable to provide a signal representative of work piece temperature. The induction heating system is operable to control the output of the induction heating system based on the plurality of signals representative of work piece temperature received from the plurality of temperature feedback devices.

Abstract: A system and method for inductively heating a work piece. The induction heating system is coupleable to at least one temperature feedback device. The temperature feedback device is disposed within the induction heating system to provide a signal representative of the temperature of an induction heating system component. The induction heating system is operable to control the output of the induction heating system based on the temperature of the induction heating system component to protect the component from heat damage.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: A method and apparatus for reducing electrical noise in an electrical signal from a temperature feedback device to an induction heating system. The induction heating system has an electrical connector that is adapted to electrically couple a temperature feedback device to a system controller and to ground via a capacitor circuit. The capacitor circuit shunts electrical noise to ground but allows a temperature signal from the temperature feedback device to be received by the system controller. A shielded extension cable to electrically couple the temperature feedback device to an induction heating system may be used. The shielding of the extension cable is electrically coupled to ground.

Abstract: A workpiece heating system having an induction heating power source and a controller. The controller is operable to control the operation of the power source according to programming instructions received from a user. The controller enables a user to establish a sequence of inductive heating operations to be performed automatically by the induction heating system from among a selection of inductive heating operations. A temperature feedback device may be included to provide the controller with the workpiece temperature. A data recorder may be provided to receive and record the workpiece temperature.

Abstract: An induction heating system having a fluid cooling unit, a power source, an induction heating device, a controller, and an alarm system to place the system in a safe condition when an improper operating condition is detected. The induction heating system may have a flow switch to detect fluid flow through the system. The system may operate to secure power to the induction heating device when cooling flow is inadequate. Alternatively, the system may increase fluid flow to provide adequate cooling flow. The controller may have a visual indicator of inadequate flow or an improper power source operating condition.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: A method and apparatus for reducing electrical noise in an electrical signal from a temperature feedback device to an induction heating system. The induction heating system has an electrical connector that is adapted to electrically couple a temperature feedback device to a system controller and to ground via a capacitor circuit. The capacitor circuit shunts electrical noise to ground but allows a temperature signal from the temperature feedback device to be received by the system controller. A shielded extension cable to electrically couple the temperature feedback device to an induction heating system may be used. The shielding of the extension cable is electrically coupled to ground.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.

Abstract: A method and apparatus for reducing electrical noise in an electrical signal from a temperature feedback device to an induction heating system. The induction heating system has an electrical connector that is adapted to electrically couple a temperature feedback device to a system controller and to ground via a capacitor circuit. The capacitor circuit shunts electrical noise to ground but allows a temperature signal from the temperature feedback device to be received by the system controller. A shielded extension cable to electrically couple the temperature feedback device to an induction heating system may be used. The shielding of the extension cable is electrically coupled to ground.

Abstract: A method and apparatus for inducing heat within a workpiece. A flexible fluid-cooled induction heating cable is used to produce a magnetic field to induce electric current in a workpiece. The induction heating cable has separate fluid and electrical connectors to separately couple cooling fluid and electric current to and from the induction heating cable. An induction heating system having a fluid cooling unit, a power source, and a flexible fluid-cooled induction heating cable having separate fluid and electrical connectors. An extension cable may be used to enable the flexible fluid-cooled induction heating cable to be used at a greater distance from the power source and the fluid cooling unit. An insulation blanket adapted for use with a specific size workpiece may be used with the flexible fluid-cooled induction heating cable.