Understanding Medium Frequency Technology (MFT)
Faced with rising energy costs, sustainability mandates, and tighter maintenance windows, industries are looking for smarter heating methods. MFT answers this need by offering precision, speed, and integration-ready control.
Medium Frequency Technology (MFT) is an induction heating method utilising electromagnetic induction to generate heat within metallic components. Unlike traditional heating methods such as furnaces or flame-based processes, MFT specifically targets the internal structure of components like bearings, gear wheels, and couplings. This method ensures precise heat distribution, significantly reduces heating time, and decreases the risk of thermal damage. MFT achieves rapid and uniform heating by directly transferring energy into the component’s metallic structure.
Efficiency of MFT in Industrial Applications
The adoption of MFT in industrial settings can significantly enhance operational efficiency through reduced heating times. Faster heating directly correlates with increased productivity, allowing industries to minimise machine downtime and associated costs. For instance, cement manufacturing, a sector characterised by frequent maintenance intervals and heavy mechanical loads, benefits notably from the precise heating capability of MFT systems, achieving measurable reductions in downtime and improved energy efficiency.
Induction heating requires the least power to deliver 1 kW of usable heat, when compared to Gas Heating and Electric Resistance Heating. The efficiency of induction heaters leads to significant energy savings. For instance, to deliver the same 1 kW of heat, electric radiant heaters require 1.82 kW, and gas heaters need 2.00 kW. Induction heating can save up to 39% and 44% in energy costs in comparison to electric and gas heating, respectively.
MFT contributes to energy conservation by ensuring the heating process is completed in a fraction of the time typically required by conventional methods. This reduction in operational downtime not only optimises productivity but also reduces overall energy consumption, aligning industrial processes with broader sustainability objectives.
Though MFT induction systems significantly enhance efficiency, their integration into industrial power systems requires attention to harmonics and interharmonics, which can affect grid stability. Academic studies recommend employing reactive power compensation, harmonic filters, and optimised inverter control strategies to mitigate these challenges effectively.
Research highlights that one significant challenge associated with integrating medium-frequency induction furnaces into industrial power systems is the generation and injection of harmonic currents into the electrical grid. Both characteristic and uncharacteristic harmonics may occur, potentially affecting power quality and grid stability. Effective mitigation typically requires employing reactive-power compensation and harmonic filtering solutions.
Safety Improvements through MFT
Worker safety is a critical consideration in industrial processes involving high temperatures. MFT induction units mitigate common hazards associated with traditional heating methods, such as open flames, hot oil baths, and handling excessively heated components.
By precisely targeting and rapidly heating only specific areas of components, MFT reduces the risk of workplace accidents and enhances the overall safety of personnel. The focused nature of MFT prevents overheating and unintentional thermal stress on components, thus safeguarding both equipment integrity and operator safety.
Applicability of MFT Across Industries
MFT has broad applicability across various heavy industries, including but not limited to automotive, aerospace, forging, heat treatment, mining, cement, steel production, and wind power generation. These industries regularly face challenges like heavy loads, harsh environmental conditions, and extensive equipment wear.
For instance, the construction materials industry experiences significant benefits from reduced bearing mounting times and maintenance intervals when employing MFT. Rapid heating times and precise temperature control enable faster, more accurate bearing installation, reducing downtime and increasing machine uptime and reliability.
A real-world example from the cement industry showcases the advantages of MFT. The maintenance team at a cement manufacturing company was struggling with the challenges of mounting bearings on roller presses. Traditional methods like oil baths and blowtorches proved to be time-consuming, costly, and posed a high risk of occupational accidents. Schaeffler proposed using its medium frequency technology (MFT) induction system—an environmentally friendly and innovative solution that heats bearings efficiently. This recommendation led to an impressive 85% reduction in time spent on maintenance work. Furthermore, the maintenance team found the process of mounting bearings significantly easier and more streamlined with the MFT system, complemented by Schaeffler's professional mounting services.
Click here to read more about this success story.
Versatility and Technical Adaptability of MFT
The technical adaptability of MFT induction systems allows for their integration into diverse industrial environments. These systems can accommodate various component sizes and configurations, ranging from small bearings to large gear assemblies, without significant adjustments to operational setups.
In large-scale applications such as raw material mills, the adaptability of MFT systems proves particularly valuable. Gearboxes comprising multiple shafts and substantial bearings benefit from consistent, precisely controlled heating processes provided by MFT systems, thereby ensuring high-quality assembly and minimising the risk of operational failures.
Conclusion
As Industry 4.0 advances, MFT stands as not just a faster induction method but a data-ready, safety-enhancing, energy-smart component of modern maintenance ecosystems.
Medium Frequency Technology (MFT) serves as a robust technological solution for addressing specific industrial challenges, offering technical advantages including rapid, precise heating, improved worker safety, reduced energy consumption, and enhanced operational efficiency. Its broad applicability and adaptability across industries underscore its value as a practical and technically sound heating solution, aligning effectively with the ongoing industrial drive towards greater productivity, safety, and sustainability.
Sources:
https://medias.schaeffler.sg/en/mount/induction-units-with-medium-frequency-technology
https://medias.schaeffler.sg/en/success-stories/0223
https://medias.schaeffler.sg/en/success-stories/0225
https://ieeexplore.ieee.org/document/5759721
https://www.thermesc.com/induction-heating-efficiency-boost-your-industrial-process?
https://medias.schaeffler.sg/en/mount/induction-units-with-medium-frequency-technology
https://www.cn-jkz.com/applications-of-medium-frequency-induction-heating.html
https://medias.schaeffler.sg/en/success-stories/0225
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