EFD Induction has for years been a trusted supplier of induction heating solutions to numerous automakers in North America and Europe. We also work with many tier-one suppliers and sub-contractors.
Induction heating is used within a variety of fields in the automotive industry such as:
Within the automotive industry, induction heating is the primary method of curing or pre-curing adhesives and sealants for closure components such as doors, hoods and trunks. Induction heating is also used to bond parts such as fenders and rear-view mirrors.
Every new car model includes an increasing number of bonded joints, making induction an even more important factor in maintaining high quality and production rates. Also, more and more modern materials are being introduced that require bonding. It’s therefore useful to know that induction heating can now be used to cure adhesives in composites-to-metal and carbon fiber-to carbon fiber joints.
EFD Induction collaborates continuously with automakers and adhesives and sealers suppliers to find new ways to develop the induction bonding process. The EFD Induction Bonding Lab in Detroit is the driving force in this cooperation. It is the only bonding lab in the induction industry and provides excellent simulations of real-world bonding.
Induction heating allows quick and accurate repetition of the desired heating cycle to the correct temperature. And the heat is easy to handle—no open flame to adjust, no need for insulation material to protect surrounding components. This, of course, promotes quality and uptime, and in the automotive industry there are numerous cases where induction has slashed brazing waste.
Working closely with many of the world’s top automakers and auto suppliers, we have to date installed more than 2,000 induction hardening solutions in the following areas:
EFD Induction has spearheaded the development of advanced frequency converters. We also offer frequency converters that run at high and low frequencies simultaneously, known as the Multi Frequency Concept (MFC)—ideal for contour hardening of cogwheels and other complex geometries.
Induction preheating is ideal for reducing the risk of cracking and hardening structures. The reason is that induction generates heat in the material itself, which means that the surrounding temperature is lower than the one generated in the material. This heat is also more accurately controlled than a gas flame. This makes it possible to reduce the temperature difference in the welding zone and achieve a lower cooling rate—particularly important with laser beam welding, where the heat is focused on one single welding point.
What’s more, preheating and welding can occur simultaneously with induction-assisted laser beam welding. You can speed up production without jeopardizing the quality.
Another area of preheating where EFD Induction operates is the shrink fitting of gear wheels. Here again the advantages of induction heating are clear—fast, accurate and controllable heat. The induction equipment is also easy to fit into your existing production line.
The automotive industry has traditionally been at the forefront of efforts to slash costs while simultaneously raising quality levels. Little wonder then that automakers and their suppliers have been aggressive adopters of induction technology.
At EFD Induction we have over the years developed and installed numerous postheating solutions for the car industry. Some examples are postheating of crankshafts, camshafts, CV joints, starter rings and camshaft gears. We also work with induction postheating for the polymerization of brake discs (GEOMET® and DACROMET® processes).
Our induction straightening solutions for the automotive industry focus on truck making and repair. Our mobile Minac system is especially suited to the latter, as it allows easy access to hard-to-reach parts, allowing rapid, concentrated heating of damaged profiles and chassis rails.
Induction straightening with EFD Induction equipment is superior in several key ways to traditional gas flame methods:
For years, induction tempering was taboo among potential users. But technical development spearheaded by EFD Induction—and real-life validation in the automotive industry—have resulted in induction tempering now being a must for a wide range of components.
A vast amount of parts can be treated with induction tempering such as camshafts, crankshafts, drive shafts, torsion bars, couplings, rocker arms, rock drills, chains, suspension arms, clutches, brake discs, steering wheels, CV joints, tulips, shock absorbers, inner and outer races, control rods, valves and output shafts.
Fast, accurate and flexible, induction tempering replaces the huge wasteful furnaces used for decades in heat treatment shops. Fatigue tests have confirmed the quality results delivered by our induction solutions.
Industrial heat treatment systems
HardLine is our range of stationary heat treatment systems for surface- and through-hardening. At the heart of each HardLine machine is an EFD Induction Sinac heat generator, the industry's most advanced induction frequency converter. These acclaimed converters help ensure optimum hardening results—day in day out, year after year.
The HardLine family includes vertical, horizontal centerless and customized machines—and serial and/or parallel compensated induction power sources with a wide range of output power and frequencies.
Universal heat generators
Choosing Sinac gives you more than the market's most advanced, most reliable induction heating systems. You also get easy access to EFD Induction’s global service, training and spare parts network. This network—which is made up of manufacturing plants, service centers and local representatives—means you are never far from qualified help and support.
Opting for Sinac also ensures you get the best possible solution tailored to your specific needs and conditions. Prior to designing your system, our engineers, metallurgists and material experts assess your requirements. Testing and computer simulation at our labs guarantee you receive equipment which is optimized to your applications and which can be painlessly integrated into existing production lines and processes.
Mobile heat generators
The Minac range of complete mobile induction systems is even easier to use than its acclaimed predecessor.
A ready-to-use system, all that has to be done upon delivery is: 1) attach a coil, 2) connect supply voltage, 3) connect cooling water. In models with closed cooling systems, only the supply voltage needs connecting.
Once installed, the Minac's clear, menu-based and multi-language control panel ensures maximum ease-of-use. Moreover, this simplified control/user interface is common to all Minac equipment.
Many Minac models come in "Twin" versions offering two independent power outputs. The Twin versions feature split control panel displays—one for each power output.
The Minac is simple to operate. Handheld transformers (HHT) feature on/off and precise power controls. In fact, the HHT is as easy to operate as a regular electric drill. Flexible, water-cooled cables connecting the HHT to the converter allow easy access to workpieces.
EFD Induction is the world’s no.1 induction hardening company. That’s good news for us. But what’s more important is why?
One key factor is our proven success at ‘package hardening’—the simultaneous hardening of three closely spaced camshaft lobes.
EFD Induction will be displaying one of its HardLine induction hardening systems at the IMTEX show to be held January 24-30 in Bangalore, India.
The show, officially known as the Indian Metal-cutting Machine Tool Exhibition, is the largest event of its kind to be held in South and South East Asia.
Dr. Hansjürg Stiele and Stefan Schubotz of EFD Induction Germany have written a detailed study of the energy efficiency of induction surface hardening. The study, which is in German, is published in connection with Härterei Kongress (Heat Treatment Congress), held this October in Wiesbaden.