Fluxtrol’s laboratory has power supplies ranging from 500 W to 50 kW with frequencies from 3 to 2000 kHz, and a large array of magnetic and thermal measurement tools, including thermal imaging cameras which aid in the ability to produce and analyze part production in a real life environment. With the ability to create production mock-ups and run prototype parts, Fluxtrol’s lab can be a useful validation tool for design concepts and production parts.
Why validate a coil
Simulation predicts temperatures, current distribution and electrical parameters, but a physical test confirms them under real conditions. In Fluxtrol’s workflow the final step compares experimental results with simulation results, which builds confidence in the model before it is used to propose changes. See the induction coils workflow and computer simulation .
What the laboratory offers
- Induction heating power supplies from 500 W to 50 kW and 3 to 2000 kHz.
- Electrical, magnetic and thermal instrumentation, including thermal imaging cameras.
- The ability to build production mock-ups and run prototype parts.
- Laboratory tests such as pin heating and robot-scanned coil trials.
The same laboratory supports Fluxtrol’s R&D services , where concepts are proven before application.
Example: robot-scanned hairpin coil
To compare heating with and without SMCs, a hairpin coil with Fluxtrol A on half its length was attached to an ABB robot arm and connected to an EFD power supply with a handheld transformer and a Dry Coolers closed-loop cooling system. The robot scanned the coil over a stainless-steel sheet, following its curvature. The Fluxtrol A section heated more than the section without SMC, in line with simulation.
Validating existing production applications
For an existing coil, the team runs an experiment to acquire data, draws the coil, uses simulation to explain the results, and compares the two. Once the model reproduces the process, a new coil design or parameters can be proposed and tested. Pre-production applications follow the same simulate, build and compare loop with a new coil.
Request prototyping or validation
Contact us about prototyping and validation services.
Real-world results
Hairpin coil tested on a robot
A hairpin coil with Fluxtrol A on half its length was scanned over a stainless-steel sheet by an ABB robot, and temperature distribution matched simulation.
- EFD power supply with handheld transformer
- Closed-loop cooling system
Robotic Induction Heating Video and Flux Concentrator Demonstration
Video of a robot-moved coil with and without concentrator, a classic magnetic flux control demonstration.
- Robot-mounted scanning coil