lnductors from EMA Indutec

best quality and reliability guaranteed

3D printing
From powder to a precision tool

3D printing from EMA Indutec concentrates on the laser sintering (selective laser melting= SLM) of
copper and stainless steel materials. The generative production is performed with a powder bed
process. The inductors and quenches to be produced are built up from powder layer by layer and
melted together using a laser.

Realizing the impossible.

Previously impossible contours and procedures can be made. 3D printing can be used to produce
complex and delicate inductors and quenches which previously were difficult and even impossible to
produce using conventional methods - all within only a few days.

Reproducibility

The hardening process depends on the exactness of the

inductor, which covers the area of the workpiece in a targeted
fashion. 3D printing guarantees the production of identical
inductors.

Longer durability and lower-cost production

The application of conventional welding and soldering pro-

cesses to inductors and quenches can cause weaknesses in
the material. These weak points are not produced by printing
using the powder bed process with lasers. 3D components
have a longer durability than conventionally-produced com-
ponents. That reduces costs and saves time.

The shortening and optimization of development times

The inside and outside inductor geometries are easier to

change and thus optimize. This achieves considerable im-
provements to electric conductivity and cooling efficiency.
Newly-developed inductors can therefore be produced in
exactly the same quality as spare inductors, but faster.

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 Research development, design,
production, service, repair, training
Research and
development

Process development Development, design Simulation, inductor design

Production

Chipping production WIG welding work

A single source
solution
Soldering on the gauge
Quality assurance

Test and bearing gauge Checking the dimensional Checking for leaks and flow
accuracy
After-Sales Service

Service Repair, also of 3D printed Training

inductors

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Inductor construction to the highest of quality standards

An inductor consists of a number of components:

• Inductor brackets in designs for high-frequency (HF) or medium-frequency (MF)

• Heating conductors in various wall strengths, shapes and dimensions
• Magnet field concentrators made of Ferrotron®, Fluxtrol® or core plates
• Bracket and supports for the heating conductor and quenches
• Quenches for the emulsion medium
• Air nozzles for shielding the hardening zone from the quenching medium
• Protective gas feeds

EMA Indutec produces inductors for induction heating systems

(as new developments or spare parts) for our own systems and
foreign systems.

Our development department is fitted with a number of work-

stations with state-of-the-art 3D-CAD and simulation software.

Production in our Inductor manufacture department is performed

in accordance with exactly determined steps. Taking the example
2 of the hair pin inductor, we begin with chipping processing of the
required parts (1) in accordance with the drawing specifications.

The required parts (1) are joined

together on the mounting (3)
from EMA Indutec using a WIG
welding device to produce a
heating conductor. The heating
conductor is then connected
with the intermediate jaws (2). 3

A gauge (4) developed by EMA Indutec is used for the exact production of the inductor.
Then, only the workpiece storage space alignment aids are required for the installation
of the inductor. This ensures a high level of precision and repeat accuracy with new
parts and repairs.

The parts joined together are soldered outside the gauge. Otherwise it would become
too hot.
4
The inductor is then ground and subject to glass bead blasting.

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The pressure resistance and pressure-tight
nature is tested on the test stand (5) in a flow 5
of 10 bar. The flow volume is later tested under
a pressure of 3 bar.

In the next step, the measurement accuracy of the inductor

is checked in the 3D measurement room with a precision
machine from Zeiss (6).

The inductors are labeled with the following information to

ensure identification (7):
• Drawing number
• Part number
• Serial number
• Year of construction

Test and positioning gauges (8) are intended for the inductors of our
8 customers. The gauge permits safe dispatch of the inductor.
The customer can also use the gauge to check the inductor and deter-
mine whether it has become bent, e.g. after a crash. The inductor can
also be stored safely and this prevents unintended deformation.
The inductors are best stored in the inductor case intended for the
purpose.

9 Induktorpass Platz für Strichcode

Ausgabedatum Induktorbau: ________________________________

Seriennummer: ________________________________

Teilenummer: ________________________________

Zeichnungsnummer: ________________________________

Bezeichnung / Werkstückart: ________________________________

Achtung: Dieser Pass verbleibt immer bei diesem Induktor!
Die weißen Felder Die grauen Einbau: Ausbau: Ausbaugrund und
werden von EMA Felder werden
Indutec ausgefüllt! vom Kunden
Datum, Name Datum,Name Bemerkungen
ausgefüllt! Zählerstand Zählerstand
1. Einbau

The use of an EMA Indutec inductor pass (9) brings a number of 1. Reparatur
EMA Indutec
2. Einbau

advantages:
Name, Datum:

• All features visible at a glance

2. Reparatur 3. Einbau
EMA Indutec
Name, Datum:

• Quality improvement through holding time check 3. Reparatur

EMA Indutec
4. Einbau

Name, Datum:

• Repair cycle easier to control

4. Reparatur 5. Einbau

• Machine downtime resulting from missing replacement

EMA Indutec
Name, Datum:

inductors can be avoided EMA Indutec GmbH • Petersbergstraße 9 • D-74909 Meckesheim • www.ema-indutec.com • Tel. +49 (0)6226 788-0

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Inductor and quench designs

Shot or semi-ring inductor Keyhole (or snowman) inductor

Ring inductor single coil Ring inductor multiple-coils Double ring inductor

Tooth-by-tooth inductor Tooth flank inductor Shape inductor

Line inductor Hairpin inductor Surface inductor

Box quench Ring quench Tooth flank quench Form quench

Interior quench Finishing quench Slit quench Axial quench

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Our trainings

The fundamentals of induction technology The fundamentals of inductor construction

How do I reduce reluctance to engage with inductor How do I reduce reluctance to engage with inductors?
technology? What is induction and how does induction How can I perform minor repairs to inductors inde-
hardening work? What do I need to comply with during pendently? What must I be aware of with inductors?
inductive hardening?

Basis training in induction technology - Basis training - theory and practice in a

theory in a one-day training course 3-day training program

Theory:
Theory:
• Induction theory
• Induction theory
• Electromagnetic characteristics
• Inductive hardening
• Materials science
• Field development
• Inductive hardening
• Inductor types
• Inductor types
• Concentrators and their effect
• Inductive tempering
• Fundamentals of inductor construction
• Inductor realization – field guiding elements
• Maintenance and handling of the inductors
Practice:
• Cutting copper components
• Bending pipes
Extended training – theory and practice in a
• Soldering
2-day training
• Welding
Theory: • Drilling
• Induction theory • Installation
• Electromagnetic characteristics
• Materials science Previous knowledge:
• Inductive hardening • Basic understanding of the mechanical
• Inductor types processing of metals
• Inductive tempering • Knowledge of welding (WIG), hard soldering,
• Inductor realization – field guiding elements soldering of metals and the bending and
• Maintenance and handling of the inductors cutting of pipes

Practice: Training centers

• Experiments with various inductor concepts
(feed, shot, steel sheeting) on one of our • EMA Indutec GmbH in Meckesheim, Germany
laboratory machines • On-site at the customer’s premises
• Evaluation of the experiments in the
laboratory
• Discussion of the results

Previous knowledge:
• Basic understanding of electrical technology
• Basic understanding of hardening technology

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 nov nezneuqe

Ideal Solutions for Heat Treatment

Inductors, E-11.2019. We reserve the right to make changes to the products and the range, as well as change of a technical nature. © Ema Indutec GmbH
Induction heating and hardening systems After Sales Service

• Economical and highly reliable systems • Qualified and knowledgeable Service Centre
• Low energy consumption per workpiece • Service hotline for troubleshooting
• Accurately reproducible hardening results • Preventive maintenance
• High throughputs • Smart remote control solutions
• Heating zones and times can be determined • Efficient spare part concepts
precisely • Customized plant-retrofit
• Heat treatment processes with low distortion • Inductor development, construction and repair
• Scale-free hardness zones due to heat treatment service
with protective gas • Training for operators, maintenance personnel
• Simple to integrate into production lines and induction experts (also on site)
• Lower expenses for production parts
• Tailor-made induction systems from a single Top quality from one source
source
• User-friendly adjustment, retrofitting and • More than 70 years of experience in heat
maintenance treatment
• Modern engineering supported by FEM simulation • Over 10,000 induction systems in long-term
• Areas of application: surface hardening, annealing operation worldwide
and tempering, heat shrinking, fixture hardening • Development and manufacture from a single source
• DIN EN ISO 9001:2015 certified
IGBT converters • Efficient project and quality management from the
first question to subsequent service
• Digital converter control
• Power range from 10 kW up to several Megawatt
• Frequencies from 5 Hz to 400 kHz
• Heating and melting EMA Indutec GmbH EMA Induction Technology
• Hardening, annealing and tempering Petersbergstraße 9 Beijing Co., Ltd.
D-74909 Meckesheim No. 17th, Xing Gu development
• Forging and forming phone: +49 6226 788 0 zone (EMA Plant area)
• High energy efficiency sales@ema-indutec.de Pinggu District
• Easy integration into production lines 101200 Beijing/China
• Customized solutions and special systems Telefon: +86 10 8070 2110
• Replacement of old and external devices ema@ema-indutec.com.cn

www.ema-indutec.com