1. Surface Induction RH/RC System
Surface Induction heating system to improve part quality and improve Injection molding cycle times
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

2. Original artwork for Nikola Tesla patent 1894
in·duc·tion heat·ing
noun
heating of a material by inducing an electric current within it.
Induction heating is the process of heating an electrically conducting object (usually a metal) by electromagnetic induction, through heat generated in the object by eddy currents (also called Foucault currents). An induction heater consists of an electromagnet, and an electronic oscillator that passes a high-frequency alternating current (AC) through the electromagnet. The rapidly alternating magnetic field penetrates the object, generating electric currents inside the conductor called eddy currents. The eddy currents flowing through the resistance of the material heat it by Joule heating. In ferromagnetic materials like iron, heat may also be generated by magnetic hysteresis losses. The frequency of current used depends on the object size, material type, coupling (between the work coil and the object to be heated) and the penetration depth.
An important feature of the induction heating process is that the heat is generated inside the object itself, instead of by an external heat source via heat conduction. Thus objects can be heated very rapidly. In addition there need not be any external contact, which can be important where contamination is an issue. Induction heating is used in many industrial processes, such as heat treatment in metallurgy, Czochralski crystal growth and zone refining used in the semiconductor industry, and to melt refractory metals which require very high temperatures. It is also used in induction cook tops for heating containers of food; this is called induction cooking.
Nikola Tesla
Original artwork for Nikola Tesla patent 1894
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

3. BENEFITS OF USING SURFACE INDUCTION RH/RC MOLDING
-Cost is less than other technologies both equipment and energy cost part to part.
-Dimensional Stability of finished part.
-Reduced warpage and stresses
-Sink reduction or elimination
-Elimination flow lines, nit lines and gate blush
-Burying glass or filler content in resin as well as class A on cellular molded products.
-Reduced and/or elimination of metallic streaking
-Enhanced texturing.
-Enhanced Chrome adhesion and overall quality.
-Piano black finishes
-Thin wall molding.
-Reduced tonnage requirements.
-Less stress on tool, ejection, slides and cams, tool is maintained at a constant tower temp.
-Enhanced cycle time. Takes less time to elevate surface temperature and less time to cool surface temperature because there is a mechanical advantage over all other RH/RC technologies. Surface induction only heats the surface whereas other technologies heat and cool the surface from the inside of the mold out to the surface.
BEFORE
AFTER
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

4. Our induction generators are designed with the manufacturer and plant maintenance personnel in mind, simple to use modular and efficient. The control system is Unix based, allowing us to log in 24/7 from anywhere in the world to troubleshoot any problems or even make processing recommendations in real time. Your quality department can collect data, maintenance can be alerted to preventive maintenance requirements. We even offer a lessons learned tryout/processing feature that stores pertinent data for retrieval and evaluation at a later date.
Advanced Features
-Adjustable frequency : Allowing the ability to heat ribs and areas where coil cannot reach , primarily used for thin wall molding.
-24/7 support: Via Network Connection, Especially helpful for first time users.
Manageable Power requirements: 480 volt 60 to 100 amp service requirements.
-Modular Design: Should you require extra KW you simple daisy chain together using Cat-5 cable allowing one operator interface to control 1 – 100 units at once.
-Simple Hook-up and Disconnect: allowing for fast mold changes.
-Modular Coils: Plug and Play on robot arm or whatever automation required for coil presentation.
-Cycle Options: Able to monitor temp or use time to heat.
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

5. OPERATOR INTERFACE
We took the needs of your production team to task when designing our Touch Screen Operator Interface, simple to use, easy to understand and packed with information. The interface is packed with info, statistical data and the ability to access our online trouble shooting guide to help through the processing of your project. At the end of the day however it is simple and to the point. Set the desired target temperature and press auto, the induction generator takes over and does the rest.
Screen Shot of AUTO OPERATION screen, Set your temp, enable cav/core if you are inducting the cavity and core and hit Auto, The Induction Generator takes over. Operator can also store past program numbers and retrieve them, or create a new one and save it for future use.
Screen Shot of PROCESS MONITOR screen, keeping operator up to date as far as temps actions and any faults.
Screen Shot of MANUAL OPERATION screen, allowing your processing technicians the ability to manually energize, advance and retract coil to finalize set-up with the robot.
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

6. COIL DESIGN AND CONSTRUCTION
Our coil construction uses a patented proprietary method. (no royalties are paid by our customers) The coil when constructed is made to stay away from the surface to be induced by 1 to 1.5 mm. This coupled with zoning requirements make the construction very complex. However because of the methods we use we can construct a replacement coil for less cost and exactly constructed as the original coil. So you never have to worry about down time or inconsistency in your plant. We recommend that a spare coil is purchased and kept in inventory in the event there is damage to the coil. Typical lead time for original coil construction is 6-8 weeks, replacement coils are less than 2 weeks and can be expedited to hours if necessary.
The coil does get warm due to the heat radiating from the surface during heat up of tool as well as a slight increase of temp when energized. Our coils are either water cooled or air cooled depending on your choice and are monitored via a K type Thermocouple to insure that if there is a failure to the cooling system the unit shuts down to insure there is no damage to the coil. The Induction unit does have safety features built in to shut itself down should it detect a water failure or air failure insuring that the coil is protected.
COIL PRESENTATION OPTIONS AND REQUIREMENTS
Coils are often no more weight than typical end of arm tooling currently installed on your robot. Most often we can simply share that space and add a motion to allow the coil to present itself during E.O.A operation. In the event that there is not enough space to achieve this method we can construct automation to come in and present before or after the robot has left the press, this can be done from underneath the tool, in from the side or even mounted directly to the moving half of the tool. These requirements are quoted and engineered should they present them selves.
The robot itself requires, (5) .25” dia. nylon tubing be rune through the cat track of the robot terminating at the E.O.A location and feeding from the portable induction generator generally located behind the press.
Robot
Coil
Plant Water
Plant Air
Plant Power
Typical Press Top View
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |

7. Equipment Specifications
MODELS
60kw
30kw
Power (kw) 60 30
Control
Unix based PC
Operator Interface
4.0 x 7.5 color
Press Interface
Cat-5
Temp Sensors
(3) K type
Unit Cooling
Water
Cooling water Pressure/Flow
18 psi/1.5 gal. min.
Coil Cooling
Water/Air
Coil Automation
(1) Pneumatic
Coil Type
Process Monitoring
Press Close/Inj/Press open/Programmable
Process Control
Allows cycle to continue when desired temp is achieved or time elapsed
Heating Current
400 – 2400 Amp
200 – 1200 Amp
Heating Frequency
Adjustable
Max input power
70 Amps
36 Amps
Service Required
480 volt 100 amp
480 volt 60 amp
Dimensions (In)
26.0 x 26.0 x 38.0
24.0 x 24.0 x 36.0
Weight (Lbs.)
175
120
24.0”(610mm) 30kw
26.0” (660mm) 60kw
36.0”(915mm) 30kw
38.0” (965mm) 60kw
24.0”(610mm) 30kw
26.0” (660mm) 60kw
30 kw
SURFACE INDUCTION TECHNOLOGIES | Milano Dr. Suite C | Macomb, Michigan | Phone: | Fax: |