Handheld High Frequency Induction Heater

1. Applicable Fields 

This device features portability, no open flame, fast heating, and simple operation, and is widely used in the following industries:

🧊 Industry

• Air conditioner and refrigerator copper pipe brazing: Connect copper pipes to copper tubes, copper tubes to iron pipes, aluminum pipes, etc., welding time 3-6 seconds

• Welding of condenser and compressor pipelines

• Brazing processes for refrigeration valves, refrigerator and freezer piping, solar accessories, etc

• Copper pipe welding for refrigeration equipment such as wine cabinets and water dispensers

⚡ The power industry

• Brazing of power transformer joints

• The end of the generator stator rod is welded to the silver-copper lead wire

🔩 Metal Processing & Heat Treatment

• Quenching: rapid heating and hardening of gears, shafts, bearings, and tool surfaces

• Annealing: Eliminates internal stress in metal and improves machinability

• Welding: brazing of cemented carbide saw blades, diamond tools, turning tools, drilling tools, etc

🚗 Automobile manufacturing

• The automotive evaporator is connected to the compressor

• Motor short-circuit ring welding

🔬 Other Applications

• Heated sleeve: The shaft sleeve after the motor rotor is heated

• On-site maintenance: oil pipeline welding and continuous oil repairs

• Mold heating, surface heat coating, weld preheating, etc

1.2 Equipment Code Reference Table

1.3 Rules for Switching Between New and Old Models

HDW-15AC→BRD-38000-1-15ACDW-40AC→BRD-38000-1-40AC

2. Working Principle

The core principle of the handheld high-frequency induction heating machine is electromagnetic induction heating. The inverter converts 50/60Hz power frequency AC into high-frequency AC of several thousand to several hundred kHz, which is then introduced into the induction coil to generate an alternating magnetic field; Conductive metal workpieces are placed within a magnetic field, where eddy currents are induced on the surface, causing the metal itself to heat up rapidly and achieve heating and brazing.

Heating follows the skin effect: the higher the frequency, the more heat concentrates on the metal surface, resulting in higher heating efficiency and a smaller heat-affected zone. The entire device uses IGBT transistor technology, with a power conversion efficiency of >90%, significantly saving energy compared to older electron tube equipment (< efficiency 50%).

Typical performance: copper tube brazing for 3–6 seconds, solder joints heat to 500–1200°C in 3–8 seconds.

3. Applicable Fields

Equipment advantages: Portable, no open flame, rapid heating, easy operation.

1. Brazing copper pipes for air conditioning and refrigerators in the refrigeration and HVAC industry (copper-to-copper, copper-iron, copper-aluminum pipelines); Welding of condenser and compressor pipelines; Brazing of refrigeration valves, freezer pipeline fittings, and solar energy accessories; Welding of refrigeration pipelines for wine cabinets and drinking water machines.

2. Brazing of transformer joints in the power industry; The end of the generator stator bar is welded to silver-copper.

3. Metal processing and heat treatment hardening: hardening the surfaces of gears, shafts, bearings, and tools; Annealing: Eliminates internal stress in metals and improves machinability; Brazing: welding cemented carbide saw blades, diamond tools, turning tools, and drilling tools.

4. Automotive manufacturing: welding of evaporators and compressor pipelines; Motor short-circuit ring brazing.

5. Other applications include hot-sleeve assembly (motor rotor hot-fitting shaft); On-site maintenance of oil and gas pipelines; Mold heating, weld preheating, surface heat coating.

4. Detailed Explanation of IGBT Transistor Technology

IGBT stands for Insulated Gate Bipolar Transistor, and is the core power device of this device. Advantages of combining two types of power devices: MOSFETs: simple driving and fast switching speed; BJT: High voltage resistance, low conduction loss.

4.1 Workflow

1. IGBT high-speed alternating switching converts 50Hz mains frequency into 20kHz~80kHz high-frequency AC;

2. High-frequency current is delivered to the handheld induction coil, generating a high-frequency alternating magnetic field;

3. Metal workpieces induce eddy currents, which rapidly heat the surface layer through the skin effect to complete brazing and heat treatment.

4.2 Core Advantages of IGBT

1. High efficiency and energy saving: conversion efficiency exceeds 90%; Saves 70% energy compared to tube equipment and 15%~25% compared to thyristor equipment.

2. Precise and stable: Fast response speed, power and time control accuracy up to 0.1%, ensuring process consistency.

3. Compact and portable: Supports high-frequency operation, significantly reduces the size of magnetic components, and enables handheld split structures.

4. Safe and reliable: built-in multiple protections for overcurrent, overvoltage, and overheating; No open flames or exhaust gases, making the working environment safer.

4.3 Comparison of Traditional Thyristor Equipment VS IGBT Equipment

5. Technical parameters of the equipment

5.1 Reference parameters for mainstream models

5.2 Power Selection Reference Table

Key points for selection: Power determines heating speed; Frequency determines heating depth; For copper tube brazing, the preferred high-frequency range is 30–100kHz.

5.3 Standard Configuration of the Entire Machine

1. Power Devices: IGBT/MOSFET all-solid-state solution, saving about 70% of electricity compared to traditional tube equipment

2. Control system: High-end models feature ARM STM32 full digital control, LCD display, and RS485 communication support

3. Protection functions: multiple protections for overvoltage, overcurrent, overheating, water shortage, and abnormal load

4. Structural features: Handheld cable 2–8 meters long, suitable for narrow space field operations

6. Advanced Model Selection Technical Guide

6.1 Frequency and Power Selection Logic

Core principle: power controls heating speed; Frequency control of heating depth and temperature difference between inside and outside.

• Brazing (refrigeration copper tubes, small tools): 50–100kHz high frequency, rapid local heating

• Surface quenching: the thinner the hardened layer, the higher the frequency of quenching; The 0.2–0.8mm hardened layer uses an ultra-high frequency of 100–250kHz

• Thermal forging: The larger the workpiece diameter, the lower the frequency; For workpieces above Φ40mm, use medium frequencies of 0.5–10kHz

6.2 Process Selection Comparison Table

Note: Selection requires comprehensive consideration of workpiece material, size, and production efficiency. It is recommended to provide precise matching of process conditions.

6.3 Power Labeling Explanation

Induction heating equipment is divided into oscillation power and actual output power, with output power ≈ oscillation power ×60%. Our equipment uniformly displays the actual output power to prevent false speculation of parameters.

6.4 Explanation of Load Duration (Temporary Load Rate).

Load Duration (Load Utilization): The proportion of equipment heating time during standard operating cycles, with a general cycle of 5–10 minutes. For example: a 60% temporary load rate means that within a 10-minute cycle, it can operate continuously for up to 6 minutes, with the remaining 4 minutes for shutdown and cooldown.

Product Highlights: High-end IGBT models support 100% temporary load rate, can operate continuously at full load for 24 hours, suitable for large-scale automated production lines.

7. Maintenance Guide

1. Daily maintenance: Regularly clean dust inside the main unit, focusing on capacitors and power devices; Check the electrical wiring tightening; Monitor water temperature and current, and do not exceed rated parameters.

2. Regular maintenance (interval 1~1.5 years) to overhaul high-voltage transformers; Testing the insulation performance of high-voltage porcelain bottles and wiring; Clean air-cooled channels and water-cooled pipelines to prevent pipeline blockage and overheating that could cause inverter failure.

8. Comprehensive Introduction to High-Frequency Welding Machines

8.1 Working Principle

High-frequency welding machines operate based on the principle of electromagnetic induction. High-frequency current enters the induction coil to generate an alternating magnetic field, generating eddy currents inside the metal workpiece. Relying on the metal's own resistance, it rapidly heats up to achieve brazing operations. Compared to gas welding and arc welding: heat is generated inside the workpiece, heating up quickly, and the heating area is controllable.

8.2 Core Advantages

1. Wide range of applicable materials: supports welding of similar and dissimilar metals (copper-copper, copper-aluminum, copper-iron, aluminum-aluminum, etc.).

2. Fast heating speed: welding can be completed at a single point in just a few seconds, with production efficiency far exceeding traditional flame welding.

3. Adjustable heating depth: By adjusting the frequency, the depth of the heating layer can be flexibly controlled, balancing precision thin-walled and thick-walled workpieces.

4. High efficiency and energy saving: IGBT all-solid-state inverter, overall machine efficiency >90%; Supports 100% temporary load rate to meet the demand for continuous mass production.

5. Stable weld quality: Heat distribution is even, weld structure is dense, and mechanical strength and conductivity are excellent.

8.3 Industry Application Summary

9. Product Summary

The handheld high-frequency induction heating machine uses IGBT solid-state induction heating technology, offering advantages such as no open flame, rapid heating, precise temperature control, portability, and energy saving, fully replacing traditional flame welding equipment. Widely used in refrigeration and HVAC, electric power, automotive manufacturing, metal heat treatment, and other industries, supporting on-site maintenance, mass production, and automated production line support.