Energy-saving induction heating device and use method thereof

Abstract

The invention discloses an energy-saving induction heating device and a using method thereof, and relates to the technical field of electromagnetic induction heating, and the energy-saving induction heating device comprises a double-layer split type induction heating coil, a magnetic field concentrator and a heat shielding plate. The induction heating coil is arranged on a plane parallel to the metal plate; the magnetic field concentrators are arranged at the ends of the corresponding induction heating coils. A heat shield plate is disposed below the induction heating coil. According to the invention, a double-layer split type coil structure is adopted, so that independent control and pilot frequency loading of the coil are realized, and the cost of a power supply required by current induction heating equipment is reduced; the effective heating distance of the induction heating device is determined by regulating and controlling the specific position of the magnetic field concentrator in the coil and the arrangement between the upper heater and the lower heater, and the energy utilization rate is increased.

Description

Technical Field

[0001] The present invention relates to the technical field of energy-saving heating, in particular to an energy-saving induction heating device and a method of using the same. Background Art

[0002] Induction heating technology is widely used in heating metal plates due to its good controllability, high yield rate and fast heating speed. Its working principle is to use the Faraday electromagnetic induction principle to generate an alternating magnetic field from an alternating current, so that an induced current, i.e. eddy current, is generated inside the heated workpiece, and the Joule heating effect of the eddy current is used to heat the workpiece.

[0003] Currently, the existing induction heating equipment has high equipment costs: induction heating devices require the use of high-quality copper coils and magnetic materials, power supply equipment manufacturing costs, R&D and design costs, installation and maintenance costs, and complex cooling system costs; high energy consumption: induction heating devices have low conversion efficiency, high energy loss, power supply equipment energy consumption, and a large amount of heat loss. Summary of the invention

[0004] In view of this, the present invention provides an energy-saving induction heating device and a method of using the same, which adopts a double-layer split coil structure to reduce the cost of the power supply required for current induction heating equipment; and improves energy utilization through process control.

[0005] The technical solution adopted by the present invention is as follows:

[0006] On the one hand, the present invention provides an energy-saving induction heating device, comprising: an upper heater and a lower heater, which are arranged side by side above and below a metal plate; the heater comprises: a double-layer split induction coil unit, a magnetic field concentrator unit, a heat shielding plate unit, a cooling plate unit, a silicon steel group unit and an induction coil cold water pipe; the double-layer split induction coil unit is arranged on a plane parallel to the metal plate; the double-layer split induction coil is two coils arranged side by side up and down; the coil can be independently controlled and loaded at different frequencies; the magnetic field concentrator unit is arranged at the corresponding end of the double-layer split induction heating coil; the heat shielding plate unit is arranged below the double-layer split induction coil; the cooling plate unit is located above the double-layer split induction coil unit on a plane parallel to the metal plate; the silicon steel group unit is located between the cooling plate unit and the heat shielding plate unit.

[0007] Furthermore, the coils can be independently controlled and loaded at different frequencies, including: the four coils of the upper heater and the four coils of the lower heater are independently controlled by four AC power supplies respectively.

[0008] Furthermore, the coils can be independently controlled and loaded at different frequencies, including: the two coils closest to the metal plate are connected to one power supply so that the two coils work in parallel; the two coils farthest from the metal plate are connected to another power supply so that the two coils work in parallel.

[0009] On the other hand, the present invention also provides a method for using the above-mentioned energy-saving induction heating device, adjusting the width, length, height of the magnetic field concentrator and the distance from the double-layer split induction coil so that the effective heating distance of the upper heater and the lower heater is the maximum effective heating distance.

[0010] Further, adjusting the width of the magnetic field concentrator comprises:

[0011] According to b = 0.78 (Δs) 0.95 Adjust the width of the magnetic field concentrator, where: b is the width of the magnetic field concentrator; Δs is the distance between the innermost coils of the double-layer split induction coil;

[0012] Adjust the length of the magnetic field concentrator, including:

[0013] According to l = 0.3·L 0.75 Adjust the length of the magnetic field concentrator, where: l is the length of the magnetic field concentrator, and L is the length of the double-layer split induction coil;

[0014] Adjust the height of the magnetic field concentrator, including:

[0015] according to Adjust the height of the magnetic field concentrator, where: h is the height of the magnetic field concentrator, n is the number of layers of the double-layer split induction coil, Δh is the spacing of the double-layer split induction coil, and r is the side length of the double-layer split induction coil;

[0016] Adjust the distance between the magnetic field concentrator and the double-layer split induction coil, including:

[0017] The distance between the magnetic field concentrator and the double-layer split induction coil is adjusted according to Δl=0.4·l, wherein: Δl is the distance between the magnetic field concentrator and the double-layer split induction coil;

[0018] The maximum effective heating distance of the upper heater and the lower heater is: S = L-2[(z+1)·r+z·Δs1+Δl], where: S is the maximum effective heating distance, Δs1 is the turn pitch of the double-layer split induction coil, and z is the number of turns of the double-layer split coil.

[0019] Furthermore, it also includes: adjusting the relative positions of the upper heater and the lower heater so that the effective heating distance between the upper heater and the lower heater is the maximum effective heating distance.

[0020] Further, adjusting the relative positions of the upper heater and the lower heater includes:

[0021] The upper heater and the lower heater adjust their relative positions by translating along the width direction of the metal sheet and in a direction perpendicular to the metal sheet.

[0022] Further, adjusting the relative positions of the upper heater and the lower heater includes:

[0023] The upper heater and the lower heater are adjusted in relative position by rotating at a preset angle around a direction perpendicular to the metal plate.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The double-layer split coil structure realizes independent control of the coil, reducing the cost of the power supply required for the current induction heating equipment.

[0026] 2. The effective heating distance of the induction heating device is determined by adjusting the specific position of the magnetic field concentrator in the coil and the arrangement between the upper and lower heaters, so that the induction heating device can be designed for metal sheets of different widths to improve energy utilization. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0028] Figure 1 It is a schematic diagram of the overall structure of the energy-saving induction heating device in an embodiment of the present invention;

[0029] Figure 2 It is a schematic diagram of the overall top view of the energy-saving induction heating device in an embodiment of the present invention;

[0030] Figure 3 It is a schematic diagram of the structure of a double-layer split induction coil in an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the structure of a magnetic field concentrator in an embodiment of the present invention;

[0032] Figure 5 A schematic diagram of a working principle of an energy-saving induction heating device in an embodiment of the present invention;

[0033] Figure 6 It is another schematic diagram of the working principle of the energy-saving induction heating device in the embodiment of the present invention;

[0034] Figure 7 It is a schematic diagram of the maximum effective distance of the present invention;

[0035] Figure 8 A schematic diagram of a moving mode of the upper and lower sensors in an embodiment of the present invention;

[0036] Fig. 9 A schematic diagram of another moving mode of the upper and lower sensors in an embodiment of the present invention;

[0037] Fig.10 A schematic diagram of another moving mode of the upper and lower sensors in an embodiment of the present invention;

[0038] Fig.11 A schematic diagram of a rotation mode of the upper and lower sensors and their projection areas on a metal plate in an embodiment of the present invention;

[0039] Fig.12 A schematic diagram of another rotation mode of the upper and lower sensors and their projection areas on the metal plate in an embodiment of the present invention;

[0040] Among them, 1. double-layer split coil unit; 2. magnetic field concentrator unit; 3. heat shielding plate unit; 4. upper coil; 5. lower coil; 6. fixing plate; 7. energy absorption and vibration reduction device; 11. main water pipe; 12. copper busbar; 13. induction coil cooling water pipe; 14. induction coil cooling water pipe interface; 15. metal plate; 22. upper heater; 23. lower heater; 24. AC power supply; 25. first control device; 26. second control device; 27. magnetic field shielding plate; 28. cooling plate unit; 29. ​​silicon steel group unit. DETAILED DESCRIPTION

[0041] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0042] It should be noted that, in the description of the present invention, the orientation or positional relationship indicated by the terms "upper", "lower", "top", "bottom", "one side", "other side", "left", "right", etc. is based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating that the device or element must have a specific orientation, be constructed and operated in a specific orientation. The terms "first", "second", etc. are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments of the present invention described here can be implemented in an order other than those illustrated or described here. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0043] like Figure 1-12 As shown, an energy-saving induction heating device in an embodiment of the present invention includes: an upper heater 22 and a lower heater 23, which are arranged side by side on the upper and lower sides of the metal plate 15.

[0044] like Figure 1-2 As shown, each heater includes: a double-layer split induction coil unit 1, a magnetic field concentrator unit 2, a heat shielding plate unit 3, a cooling plate unit 28, a silicon steel group unit 29 and an induction coil cold water pipe 13; the double-layer split induction coil unit 1 is arranged on a plane parallel to the metal plate 15; the magnetic field concentrator unit 2 is arranged at the corresponding end of the double-layer split induction heating coil 1; the heat shielding plate unit 3 is arranged below the double-layer split induction coil 1; the cooling plate unit 28 is located above the double-layer split induction coil unit 1 on a plane parallel to the metal plate 15; the silicon steel group unit 29 is located between the cooling plate unit 28 and the heat shielding plate unit 3; the induction coil cooling water pipe 13 is located between the magnetic field concentrator unit 2 and the copper bus 12, and the double-layer split induction coil 1 is arranged with four induction coil cooling water pipe interfaces which are respectively connected to the main water pipe 11 through the induction coil cooling water pipe 14.

[0045] like Figure 3 As shown, the double-layer split induction coil 1 is two coils arranged side by side, including an upper coil 4 and a lower coil 5; the cross-sectional shape of the double-layer split induction coil 1 can be rectangular, circular, trapezoidal, etc. The double-layer split induction coil also includes: a copper bar 12 and a coil cooling water pipe interface 14, wherein the copper bar 12 is located at the end of the coil, and the coil cooling water pipe interface 14 is also arranged at a position near the copper bar 12 at the end of the coil, for connecting the induction coil cooling water pipe 13.

[0046] like Figure 4 As shown, the magnetic field concentrator unit 2 is fixed above the magnetic field shielding plate 27 by a fixing plate 6, and the magnetic field shielding plate 27 is located on both sides of the magnetic field concentrator unit 2; the energy absorption and vibration reduction device 7 is arranged in the gap between the magnetic field concentrator 2 and the magnetic field shielding plate 27, and the material of the energy absorption and vibration reduction device 7 is foamed aluminum, and its energy absorption and vibration reduction performance reduces the mechanical vibration of the magnetic field concentrator 2 to avoid vibration damage during induction heating work, and the electromagnetic shielding performance of the foamed aluminum prevents the magnetic field lines from escaping, and the good thermal insulation performance is suitable for induction heating devices.

[0047] The above energy-saving induction heating device includes the following two working modes:

[0048] The first working mode: Figure 5 As shown, the four coils of the upper heater 22 and the lower heater 23 are independently controlled by four AC power supplies 24 and loaded at different frequencies; the first control device 25 realizes the synchronous control of the phases of the two AC power supplies 24 of the heater; the second control device 26 realizes the synchronous control of the phases of the two groups of power supplies 24 of the upper heater 22 and the lower heater 23, thereby reducing the parameter requirements of the induction heating device on the circuit load, reducing the required power cost and energy consumption, and realizing the economic energy saving of the induction heating device.

[0049] The second working mode: Figure 6 As shown, the inner coils (i.e., the two coils closest to the metal plate) are connected to an AC power supply 24 so that the two coils work in parallel; at the same time, the outer coils (i.e., the two coils farthest from the metal plate) are connected to an AC power supply 24 so that the two coils work in parallel; the control device 26 realizes synchronous control of the phases of the two groups of power supplies 24; and realizes the temperature uniformity in the thickness direction of different metal plates 15 through different combinations of low frequency and medium frequency, medium frequency and high frequency or the same frequency.

[0050] like Figure 7 As shown, the maximum effective heating distance is the distance between the upper heater 22 and the lower heater 23 outside the magnetic field concentrator 2. By adjusting the effective heating distance, the design of the energy-saving induction heating device and the control of the heating effect can be achieved.

[0051] The side length of the double-layer split induction coil 1 is limited to r (the side length of the square coil, the diameter of the circular coil), the spacing of the double-layer split induction coil 1 (the air gap between the upper coil and the lower coil) is limited to Δh, the spacing of the innermost coils of the double-layer split induction coil 1 is limited to Δs, and the length of the double-layer split induction coil 1 is limited to L.

[0052] The width of the magnetic field concentrator 2 is b, and the value of b is affected by Δs. The control strategy is b = 0.78·(Δs) 0.95; The length of the magnetic field concentrator 2 is l, the value of l is affected by L, and its control strategy is l = 0.3·L 0.75 ; The height of the magnetic field concentrator 2 is h, and the value of h is affected by the number of layers n of the double-layer split induction coil 1. Its control strategy is The distance between the magnetic field concentrator 2 and the double-layer split induction coil 1 is Δl. The value of Δl is affected by the double-layer split induction coil l, and the control strategy is Δl=0.4·l.

[0053] The maximum effective heating distance is S, the turn distance of the double-layer split coil is Δs1, and the number of turns of the double-layer split induction coil is z;

[0054] The effective heating distance S is affected by the double-layer split induction coil 1, and its control strategy is S=L-2[(z+1)·r+z·Δs1+Δl]; the formula is used to determine the maximum effective distance S of the energy-saving induction heating device, thereby realizing the design of the corresponding energy-saving induction heating device according to the maximum width size of the metal plate 15.

[0055] like Figure 8-10 As shown, the upper heater 22 and the lower heater 23 can adjust their relative positions by translating along the width direction of the metal plate 15 and in a direction perpendicular to the metal plate 15; Figure 11-12 As shown, the upper heater 22 and the lower heater 23 can adjust their relative positions by rotating a certain angle around the direction perpendicular to the metal sheet 15. By adjusting the positional relationship between the upper and lower heaters, the gap and effective heating distance S between the double-layer split induction coil 1 and the metal sheet 15 are regulated to meet the heating requirements of metal sheets 15 of different widths and different materials. By adjusting the angles of the upper heater 22 and the lower heater 23, the projection area of ​​the upper heater 22 and the lower heater 23 on the metal sheet 15 becomes larger, and the larger the heating area, the better the temperature rise effect, which expands the scope of use of the energy-saving induction heating device.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An energy-saving induction heating device, It is characterized in that include: The upper heater and the lower heater are arranged side by side above and below the metal plate; the heater comprises: a double-layer split induction coil unit, a magnetic field concentrator unit, a heat shielding plate unit, a cooling plate unit, a silicon steel group unit and an induction coil cold water pipe; the double-layer split induction coil unit is arranged on a plane parallel to the metal plate; the double-layer split induction coil is two coils arranged side by side up and down, and the coils can be independently controlled and loaded at different frequencies; the magnetic field concentrator unit is arranged at the corresponding end of the double-layer split induction heating coil; the heat shielding plate unit is arranged below the double-layer split induction coil; the cooling plate unit is located above the double-layer split induction coil unit on a plane parallel to the metal plate; the silicon steel group unit is located between the cooling plate unit and the heat shielding plate unit.

2. An energy-saving induction heating device according to claim 1, It is characterized in that The coils can be independently controlled and loaded at different frequencies, including: the four coils of the upper heater and the lower heater are independently controlled by four AC power supplies respectively.

3. An energy-saving induction heating device according to claim 1, It is characterized in that The coils can be independently controlled and loaded at different frequencies, including: the two coils closest to the metal plate are connected to one power supply so that the two coils work in parallel; the two coils farthest from the metal plate are connected to another power supply so that the two coils work in parallel.

4. A method for using the energy-saving induction heating device according to any one of claims 1 to 3, It is characterized in that The width, length, height of the magnetic field concentrator and the distance from the double-layer split induction coil are adjusted so that the effective heating distance of the upper heater and the lower heater is the maximum effective heating distance.

5. The method according to claim 4, It is characterized in that Adjust the width of the magnetic field concentrator, including: According to b = 0.78 (Δs) 0.95 Adjust the width of the magnetic field concentrator, where: b is the width of the magnetic field concentrator; Δs is the distance between the innermost coils of the double-layer split induction coil; Adjust the length of the magnetic field concentrator, including: According to l = 0.3·L 0.75 Adjust the length of the magnetic field concentrator, where: l is the length of the magnetic field concentrator, and L is the length of the double-layer split induction coil; Adjust the height of the magnetic field concentrator, including: according to Adjust the height of the magnetic field concentrator, where: h is the height of the magnetic field concentrator, n is the number of layers of the double-layer split induction coil, Δh is the spacing of the double-layer split induction coil, and r is the side length of the double-layer split induction coil; Adjust the distance between the magnetic field concentrator and the double-layer split induction coil, including: The distance between the magnetic field concentrator and the double-layer split induction coil is adjusted according to Δl=0.4·l, wherein: Δl is the distance between the magnetic field concentrator and the double-layer split induction coil; The maximum effective heating distance between the upper heater and the lower heater is: S = L-2[(z+1)·r+z·Δs 1 +Δl], where: S is the maximum effective heating distance, Δs 1 is the turn pitch of the double-layer split induction coil, and z is the number of turns of the double-layer split coil.

6. The method according to claim 4, It is characterized in that Also includes: Adjust the relative positions of the upper heater and the lower heater so that the effective heating distance between the upper heater and the lower heater is the maximum effective heating distance.

7. The method according to claim 4, It is characterized in that Adjust the relative positions of the upper heater and the lower heater, including: The upper heater and the lower heater adjust their relative positions by translating along the width direction of the metal sheet and in a direction perpendicular to the metal sheet.

8. The method according to claim 4, It is characterized in that Adjust the relative positions of the upper heater and the lower heater, including: The upper heater and the lower heater are adjusted in relative position by rotating at a preset angle around a direction perpendicular to the metal plate.

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