Eye alignment sensor for induction brazing

Abstract

The invention discloses an alignment inductor for induction brazing. The alignment inductor comprises an inductor base, a hollow copper pipe with a square outer part and a round inner part, a ferrite magnetizer, a polytetrafluoroethylene insulating sheet and a reinforcing rib. A heating opening is formed in the middle of the square-outside and round-inside hollow copper pipe in a winding mode, and magnetic field concentration and even distribution are achieved through coil bending and spiral winding design. The ferrite magnetizers are symmetrically arranged to enhance a magnetic field; the reinforcing ribs reinforce the structure to prevent deformation; the teflon insulating sheet isolates current to avoid short circuit. By optimizing the structural design, the heating speed, the welding precision and the heat efficiency are remarkably improved, meanwhile, energy consumption and environmental pollution are reduced, and the device is suitable for precision part welding and automatic production requirements and has the technical advantages of being efficient, safe and environmentally friendly.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of high-frequency welding equipment, and particularly relates to an eye inductor for induction brazing. BACKGROUND

[0002] In the refrigeration industry and related manufacturing fields, the welding process of dispensers, single-pass tubes and other fittings plays a key role in product quality and production efficiency. Currently, these fittings are mostly connected using traditional brazing processes, with oxygen-acetylene flame welding being the main method. However, this traditional process has many shortcomings. First, the wide range of flame heating and the large heat-affected zone can easily cause the base material to overheat and deform, thereby adversely affecting the welding quality of the workpiece. Second, in a high-temperature environment, the surface of the workpiece is easily oxidized, which may leave corrosive impurities, further affecting the durability and reliability of the welded parts. In addition, the energy conversion efficiency of traditional brazing processes is low, the long-term use cost is high, and it relies on manual operation, making it difficult to ensure temperature uniformity, resulting in unstable weld quality. More seriously, open flame operations also carry the risk of combustion and explosion, and the waste gas produced by combustion not only poses a threat to human health, but also pollutes the environment. Therefore, developing an efficient, safe and environmentally friendly welding technology has become a technical problem to be solved. The present application aims to overcome the above-mentioned defects and provide a solution that can achieve rapid heating, high-precision welding and significantly reduce energy consumption and environmental pollution. SUMMARY

[0003] The present application aims to provide an eye inductor for induction brazing to overcome the deficiencies in the prior art.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical solutions: An eye inductor for induction brazing, comprising an outer square and inner circular hollow copper tube, a ferrous magnetic conductor, a reinforcing rib, a tetrafluoroethylene insulating sheet and an inductor base, wherein: The outer square and inner circular hollow copper tube is the core component of the inductor, and is fixedly connected to the inductor base at both ends and wound into a heating opening in the middle. The design of the heating opening makes the coil vortex direction consistent, thereby forming a uniform magnetic field with uniform magnetic field direction. Further, the outer square and inner circular hollow copper tube is used to transport current to form a concentrated magnetic field at the heating opening, so as to achieve rapid heating of the workpiece to be welded.

[0005] Further, the ferrite magnetic conductor is circular, and the ferrite magnetic conductor is clamped in the inner diameter of the outer square inner circular hollow copper tube and fixedly connected with the inner ring hollow copper tube, and two ferrite magnetic conductors are symmetrically arranged on both sides. In particular, the ferrite magnetic conductor serves to enhance and concentrate the magnetic field, improve the uniformity of the magnetic field distribution, and thus improve the welding efficiency and precision. The symmetrical arrangement of the ferrite magnetic conductor ensures the symmetry of the magnetic field, avoiding welding quality problems caused by uneven magnetic field distribution.

[0006] In particular, the inductor base is a symmetrical structure for mounting and fixing the coaxial transformer and the outer square inner circular hollow copper tube. The inductor base not only provides stable support, but also ensures the stability of the inductor during operation through its symmetrical design. Further, the inductor base is provided with a reinforcing rib, which is wrapped around the outer sidewall of the outer square inner circular hollow copper tube, for reinforcing the overall structural strength of the inductor to prevent deformation caused by long-term use. Through the design of the reinforcing rib, the service life of the inductor is significantly prolonged, while the stability of the magnetic field distribution during welding is ensured.

[0007] Further, the four-fluorine insulating sheet is fixedly arranged in the gap at the connection between the outer square inner circular hollow copper tube and the inductor base, for isolating the two ends of the outer square inner circular hollow copper tube and avoiding direct conduction. The arrangement of the four-fluorine insulating sheet ensures the normal circulation of current in the inductor, while avoiding safety hazards caused by short circuit. The selection of four-fluorine material is based on its excellent insulation performance and high-temperature resistance characteristics, which can meet the harsh requirements in high-frequency welding environment.

[0008] In particular, the heating opening is wound from the middle part of the outer square inner circular hollow copper tube, with the opening facing forward and the eddy current directions of the coils on the left and right sides being the same. Through this design, a uniform magnetic field is formed at the heating opening for heating the workpiece to be welded. The design of the heating opening not only improves the concentration of the magnetic field, but also facilitates the positioning and placement of the workpiece to be welded, thereby optimizing the convenience and efficiency of the welding operation. Further, the coils on both sides of the heating opening are hollow copper tubes wound in a circular spiral, with the same direction of current, and the magnetic field generated by the spiral winding of the hollow copper tube is more concentrated, effectively concentrating the heating position and improving the thermal efficiency.

[0009] The working principle of the present application is as follows: when the coaxial transformer is started, the outer square inner circular hollow copper tube delivers a directional current, and the two coplanar coils opposite the heating opening form a uniform magnetic field with consistent magnetic field direction. According to the "eddy current effect" of electromagnetic induction, the workpiece to be welded placed in the middle of the heating opening will rapidly heat up under the action of the magnetic field, thereby achieving efficient and high-quality welding.

[0010] Compared with the prior art, the present application has the following advantages: The structural features of the eye inductor for induction brazing (straight, avoidance) are as follows: the rear end of the inductor is a symmetrical inductor base for mounting and fixing a coaxial transformer, the front end is a U-shaped opening, the opening is bent towards the left and right sides, the eddy current directions of the coils are the same, the ferrite magnetic conductors are T-shaped, the middle protruding part is clamped into the inner diameter of the inductor coil, and the left and right sides are clamped with two ferrite magnetic conductors respectively, which is called a symmetrical form. A reinforcing rib is arranged in the middle of the inductor for reinforcing the strength of the inductor itself, thereby increasing the service life of the inductor and preventing the inductor from deforming due to long-term use, thereby reducing the precision and service life.

[0011] Fast heating speed: through electromagnetic induction direct heating, the heating speed of the workpiece to be welded reaches seconds, which is 3-5 times higher than traditional flame brazing. High welding precision: due to the concentration and uniform distribution of the magnetic field, the heat-affected zone is significantly reduced, and the deformation of the workpiece is effectively controlled, which is suitable for the welding needs of precision parts. Low energy consumption: high energy conversion efficiency, energy consumption cost is only one third of traditional flame brazing, which significantly reduces the long-term use cost. High safety: no open flame operation, avoiding the risk of combustion and explosion; no waste gas emission, reducing workshop pollution by 90%, effectively improving the working environment and reducing the harm to human health. Easy to integrate: compact inductor structure, can be linked with robots to realize automatic mass production, suitable for the needs of modern industrial production. Good environmental protection: compared with traditional brazing process, the invention greatly reduces the negative impact on health and environment, meeting the requirements of green and environmental protection.

[0012] The magnetic field generated by the spiral winding of the hollow copper pipe is more concentrated, effectively concentrating the heating position and improving the thermal efficiency.

[0013] In summary, the present application solves many problems existing in the traditional brazing process through unique structural design and working principle, has wide application prospect and significant technical advantages. BRIEF DESCRIPTION OF DRAWINGS Figure 1 It is the front view of the present application; Figure 2 It is the three-dimensional structure schematic diagram of the present application; Figure 3 It is the top view of the present application.

[0014] Explanation of the attached drawings: 1, outer square and inner circle hollow copper pipe; 2, ferrite magnetic conductor; 3, reinforcing rib; 4, four fluorine insulating sheet; 5, inductor base; 6, heating opening. DETAILED DESCRIPTION

[0015] The present application will be described in detail below in combination with each embodiment shown in the drawings: The structure and working principle of the eye induction heater for induction brazing are designed to solve the problems of wide heating range, large heat-affected zone, unstable welding quality, high energy consumption and serious environmental pollution in traditional brazing process. The specific embodiments of the present application are described in detail below in combination with the component numbers marked in the drawings and the accompanying drawings. Figures 1 to 3

[0016] In practical applications, the eye induction heater of the present application includes an outer square and inner circular hollow copper tube 1, a ferrite magnetic conductor 2, a reinforcing rib 3, a tetrafluoroethylene insulating sheet 4, and an induction heater base 5. These components are optimized in design and precisely assembled to ensure the efficiency and reliability of the induction heater in a high-frequency welding environment. First, the induction heater base 5, as the basic part of the entire device, adopts a symmetrical structure design, and its upper surface is provided with a mounting groove for fixing the coaxial transformer and the outer square and inner circular hollow copper tube 1. The symmetrical design of the induction heater base 5 ensures that the entire induction heater remains stable during operation, avoiding deformation or magnetic field deviation caused by asymmetric stress. In addition, the reinforcing rib 3 is provided on the induction heater base 5, which is wrapped around the outer sidewall of the outer square and inner circular hollow copper tube 1 and is integrally formed with the induction heater base 5. The reinforcing rib 3 serves to enhance the overall rigidity of the induction heater, preventing irreversible deformation of the outer square and inner circular hollow copper tube 1 due to long-term use, thereby prolonging the service life of the induction heater and ensuring the stability of the magnetic field distribution.

[0017] The outer square and inner circular hollow copper tube 1 is the core component of the present application, and its two ends are fixed in the mounting groove of the induction heater base 5 through threaded connections, and the middle part is wound into a heating opening 6. The heating opening 6 is U-shaped, with the opening facing forward and the left and right coils being bent coils with a bending angle of 90° to 120°. This design of bent coils makes the eddy current direction consistent at the heating opening 6, forming a uniform magnetic field with uniform magnetic field direction. Further, the outer square and inner circular hollow copper tube 1 is wound in a circular spiral to form two side coils, and the number of turns of the two side coils is 3 to 5 turns with the same current direction. The design of circular spiral winding improves the magnetic field concentration, effectively limits the heating position to the target area of the workpiece to be welded, thereby improving the thermal efficiency and reducing energy loss. As shown in FIG. 2, the winding method of the outer square and inner circular hollow copper tube 1 is clearly visible, and the coil structure formed by the circular spiral winding is helpful for the concentrated distribution of the magnetic field. Figure 2

[0018] ​​The iron-oxygen magnetic conductor 2 is circular and is clamped in the inner diameter of the outer square inner circular hollow copper pipe 1 and is fixedly connected with the inner ring hollow copper pipe. The material of the iron-oxygen magnetic conductor 2 is iron-oxygen body, which has the characteristics of high magnetic permeability and low loss. Further, two iron-oxygen magnetic conductors 2 are symmetrically arranged on the two sides respectively, and a spacing is arranged between the two iron-oxygen magnetic conductors 2. This symmetrical arrangement ensures the symmetry of the magnetic field, avoiding the welding quality problem caused by uneven magnetic field distribution. The function of the iron-oxygen magnetic conductor 2 is to enhance and concentrate the magnetic field, improve the uniformity of the magnetic field distribution, and thus improve the welding efficiency and precision. Figure 3 The symmetrical arrangement of the iron-oxygen magnetic conductor 2 and the connection relationship between the iron-oxygen magnetic conductor 2 and the outer square inner circular hollow copper pipe 1 are clearly shown.

[0019] The tetrafluoro insulating sheet 4 is arranged in the gap between the outer square inner circular hollow copper pipe 1 and the inductor base 5, and is used to isolate the two ends of the outer square inner circular hollow copper pipe 1 to avoid direct conduction. The thickness of the tetrafluoro insulating sheet 4 is 1mm to 2mm, and the width is 5mm to 8mm. The material of the tetrafluoro insulating sheet 4 is polytetrafluoroethylene, which has excellent insulation performance and high temperature resistance. Further, the tetrafluoro insulating sheet 4 is fixedly connected between the outer square inner circular hollow copper pipe 1 and the inductor base 5 by epoxy resin adhesive, which ensures the reliability and safety in the high-frequency welding environment. Figure 1 The position of the tetrafluoro insulating sheet 4 and the connection relationship between the tetrafluoro insulating sheet 4 and the outer square inner circular hollow copper pipe 1 and the inductor base 5 are shown.

[0020] The working process of the present application is as follows: when the coaxial transformer is started, the outer square inner circular hollow copper pipe 1 transmits current in one direction, forming a concentrated and uniform magnetic field at the heating opening 6. According to the "eddy current effect" of electromagnetic induction, the workpiece to be welded placed in the center of the heating opening 6 will rapidly heat up under the action of the magnetic field, thereby realizing efficient and high-quality welding. In particular, the design of the bent coil of the heating opening 6 makes the magnetic field concentrate in the target area of the workpiece to be welded, reducing the possibility of heat spreading to non-target areas, thereby reducing the heat affected zone and the deformation amount of the workpiece. In actual operation, the workpiece to be welded is placed at the center position of the heating opening 6, and by adjusting the position and attitude of the workpiece, the best coupling with the magnetic field is ensured. Then, the coaxial transformer is started, and the current in the outer square inner circular hollow copper pipe 1 rapidly generates a magnetic field, and the surface of the workpiece rapidly heats up due to the eddy current effect. Since the magnetic field is concentrated and uniformly distributed, the temperature of the welding area can quickly reach the melting point required for brazing, while the temperature of the surrounding area changes little, thereby significantly reducing the range of the heat affected zone.

[0021] The safety of the present application is also significantly improved. The absence of open flame operation avoids the risk of combustion and explosion, and the absence of exhaust gas emission reduces the pollution of the workshop by 90%, effectively improving the working environment and reducing the harm to human health. In practical application, the air quality monitoring data in the workshop shows that after using the inductor of the present application, the concentration of carbon monoxide and nitrogen oxides in the air is significantly reduced, meeting the requirements of national environmental protection standards. In addition, the inductor structure is compact, can be linked with the robot to realize automatic mass production. By integrating the inductor with the mechanical arm, automatic positioning, welding and detection of the workpiece can be realized, further improving the production efficiency and welding quality.

[0022] In summary, the present application solves many problems existing in the traditional brazing process through unique structural design and working principle. Through the symmetrical design of the inductor base 5, the circular spiral winding of the outer square and inner circular hollow copper pipe 1, the symmetrical arrangement of the ferrite magnetic conductor 2 and the high-efficiency insulation of the four-fluorine insulation sheet 4, the technical targets of uniform magnetic field distribution, heat efficiency improvement and welding precision improvement are realized. Practical application shows that the present application has the advantages of fast heating speed, high welding precision, low energy consumption, good safety, easy integration and strong environmental protection, etc., meets the needs of modern industrial production, has wide application prospect and technical value.

Claims

1. A pair of eyes inductor for induction brazing, characterized by, It includes: The inductor base; The outer square inner circle hollow copper pipe, both ends of which are fixedly connected to the inductor base, and the middle part of which is wound to form a heating opening, which is used for current transmission; Ferrite magnetic conductor, which is arranged in the inner diameter of the outer square inner circle hollow copper pipe; Four fluorine insulation sheet, which is arranged in the gap between the outer square inner circle hollow copper pipe and the inductor base.

2. A pair of eyes inductor for induction brazing according to claim 1, characterized in that, The heating opening is formed by winding the middle part of the outer square inner circle hollow copper pipe, and the heating opening is designed to make the coil eddy current direction consistent.

3. A pair of eyes inductor for induction brazing according to claim 2, characterized in that, The heating opening is open to the front, and the left and right sides are bending coils, which facilitates the positioning of the workpiece.

4. A pair of eyes inductor for induction brazing according to claim 3, characterized in that, The two side coils of the heating opening are formed by winding the hollow copper pipe in a circular spiral, and the current direction is the same.

5. A pair of eyes inductor for induction brazing according to claim 1, characterized in that, The ferrite magnetic conductor is circular, clamped in the inner diameter of the outer square inner circle hollow copper pipe and fixedly connected with the inner circle hollow copper pipe to concentrate the magnetic field.

6. A pair of eyes inductor for induction brazing according to claim 5, characterized in that, Two ferrite magnetic conductors are symmetrically arranged on both sides of the ferrite magnetic conductor to ensure the symmetry of the magnetic field.

7. A pair of eyes inductor for induction brazing according to claim 1, characterized in that, The inductor base is a symmetrical structure, which is used for installing and fixing the coaxial transformer and the outer square inner circle hollow copper pipe, and provides stable support.

8. A pair of eyes inductor for induction brazing according to claim 7, characterized in that, The inductor base is provided with a reinforcing rib, which is wrapped on the outer side wall of the outer square inner circle hollow copper pipe, which is used to reinforce its structure.

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