A multi-field coupling optimized induction heating device and method for square steel

Abstract

This invention discloses a multi-field coupling optimized induction heating device and method for square steel, including an induction coil group, a power adjustment component, a temperature control monitoring module, and a control unit. The induction coil group is used to mount the square steel and includes multiple induction coils that are spaced apart along the axial direction of the square steel. The power adjustment component includes multiple power adjustment units, the number of which corresponds one-to-one with the number of induction coils. Each power adjustment unit is electrically connected to its corresponding induction coil. The temperature control monitoring module includes multiple sensor groups, the number of which corresponds one-to-one with the number of induction coils. Each sensor group is used to monitor the core-to-surface temperature difference and circumferential temperature difference of a corresponding portion of the square steel during the heating process. The control unit is electrically connected to the temperature control monitoring module and the power adjustment units. This method can suppress temperature differences at the source of heat generation, achieving uniform heating without the need for subsequent forced cooling.

Description

Technical Field

[0001] This invention relates to the field of steel induction heating technology, specifically to a multi-field coupled optimized square steel induction heating device and heating method. Background Technology

[0002] In high-precision steel processing fields such as artillery shell production, the uniformity of induction heating of square steel directly affects the product quality and production efficiency of subsequent processing steps such as punching and drawing. Existing square steel induction heating devices suffer from the following main technical defects: First, the core-to-surface temperature difference control accuracy is insufficient; traditional devices typically have a core-to-surface temperature difference of ±20℃, which cannot meet the requirements of high-precision processing for uniform billet temperature. Second, the control of the upper and lower temperature differences relies on forced temperature equalization devices such as water curtains, resulting in high energy consumption, large maintenance workload, and increased production costs and maintenance difficulty. Third, due to the sharp corner effect of square steel, the magnetic field distribution in the circumferential direction is uneven, making temperature equalization control difficult and becoming a key bottleneck restricting heating quality.

[0003] In existing technologies, some solutions attempt to improve temperature uniformity by adjusting the number of coil turns or adding cooling devices. However, these solutions lack systematic optimization through multiphysics simulation and finite element methods, failing to fundamentally address the temperature uniformity issues across the core surface, top and bottom (or along the length of the square steel), and circumference. Furthermore, they suffer from poor adaptability and complex adjustments. Therefore, there is an urgent need for an induction heating technology based on multi-field coupling optimization to comprehensively improve the heating uniformity of square steel while reducing equipment operating costs. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-field coupling optimized induction heating device and method for square steel to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this disclosure provides a multi-field coupling optimized square steel induction heating device, including an induction coil group, a power regulation component, a temperature control monitoring module, and a control unit; The induction coil group is used to be sleeved on the square steel, and the induction coil group includes multiple induction coils, which can be arranged at intervals along the axial direction of the square steel. The power adjustment component includes multiple power adjustment units, the number of which corresponds one-to-one with the number of induction coils, and each power adjustment unit is electrically connected to the corresponding induction coil. The temperature control monitoring module includes multiple sensor groups, the number of which corresponds one-to-one with the number of induction coils. Each sensor group is used to monitor the core-surface temperature difference and circumferential temperature difference of the corresponding part of the square steel during the heating process. The control unit is electrically connected to the temperature control monitoring module and the power adjustment component, and is used to adjust the core surface temperature difference and circumferential temperature difference of the corresponding portion of the square steel.

[0006] Optionally, each of the sensor groups includes multiple temperature sensors, which can be arranged at circumferential intervals along the square steel.

[0007] Optionally, the induction coil is constructed as a hollow copper tube, and the surface of the induction coil is coated with an insulating and high-temperature resistant coating.

[0008] Optionally, the output power of the power regulation unit is 0-1500kW, and the response speed of the power regulation unit is ≤0.5s.

[0009] Optionally, the square steel induction heating device further includes an annular magnetic field adjustment mechanism; The annular magnetic field adjustment mechanism is sleeved on the induction coil group. The annular magnetic field adjustment mechanism includes multiple magnetic field shielding plates, which are arranged at intervals along the circumference of the induction coil group.

[0010] Optionally, the magnetic field shielding sheet is constructed as an arc-shaped plate structure.

[0011] Optionally, the square steel induction heating device further includes a coil fixing assembly, which includes a support base, a positioning flange, and a locking element; The positioning flanges are respectively fitted at both ends of the induction coil group, and each positioning flange is connected to the support seat on the furnace shell through the locking member.

[0012] This disclosure also provides a method for induction heating of square steel, based on the above-mentioned induction heating device for square steel, comprising the following steps: S1: Establish a multi-physics heating model for the square steel to be heated, input the material parameters, size parameters and target temperature parameters of the square steel, simulate the temperature change curves of the steel core and surface under different power distributions, and fit to obtain the initial power ratio parameters of the multi-section induction coil group so that the core-surface temperature difference of the square steel is controlled within the preset range during the initial heating stage. S2: Based on the Maxwell equation finite element algorithm, simulate the magnetic field distribution under the sharp corner effect of square steel, determine the number and position of magnetic field shielding plates and the spacing between adjacent induction coils in the ring magnetic field adjustment mechanism, so as to balance the magnetic field distribution in the circumferential direction. S3: The square steel to be heated is inserted into the induction coil group and positioned and fixed by the coil fixing assembly; S4: Start each of the power regulation units and output power according to the initial power ratio parameters; S5: During the heating process, the temperature control monitoring module is activated, and the core surface temperature difference data and circumferential temperature difference data of the corresponding area of ​​the square steel are collected in real time through each of the sensor groups and transmitted to the control unit; S6: The control unit calculates the compensation power required for each area based on the monitoring data of each area and the preset target temperature curve, and adjusts the output power of the corresponding power adjustment unit until the overall temperature of the square steel reaches the processing requirements and the temperature difference between each area is stable within the set range, so as to complete the heating process. S7: Turn off each of the power adjustment units and remove the square steel for subsequent processing.

[0013] Optionally, in S1, the preset range is an absolute value of the core-to-surface temperature difference ≤ 15℃; In S6, the set range includes: the absolute value of the core-to-surface temperature difference on the cross-section of the square steel is ≤15℃, and the absolute value of the circumferential temperature difference at the edge of the cross-section of the square steel is ≤20℃. The required processing temperature range is 1000-1170℃.

[0014] Compared with existing technologies, the advantages of this invention are as follows: By using an induction coil group, power adjustment component, temperature control monitoring module, and control unit, multiple induction coils can be used to achieve precise heating control of the square steel's heating area. Furthermore, multiple sensor groups can be used to monitor in real time the core-to-surface temperature difference (i.e., the difference between the center temperature and surface temperature of the square steel cross-section) and the circumferential temperature difference (i.e., the temperature difference between different circumferential positions of the square steel cross-section, especially between sharp corners and edges) of each independent heating section. Simultaneously, multiple power adjustment units can be used to adjust the energy input of each independent heating section as needed. Therefore, the control unit can dynamically calculate and generate independent power adjustment commands for each area based on the real-time core-to-surface and circumferential temperature difference data monitored by the temperature control monitoring module, combined with a preset multi-physics coupling optimization model, and then independently drive the corresponding power adjustment unit to adjust the input power of each induction coil. Specifically, when a large circumferential temperature difference is detected in a certain section (such as a sharp corner temperature significantly higher than the edge surface), the control unit can reduce the coil power in that area to weaken the skin effect, thereby suppressing overheating of the sharp corner and balancing the circumferential temperature of the square steel. When a core-to-surface temperature difference is detected in a certain section, the control unit can control the electromagnetic parameters of the induction coil (such as heating power density, current frequency, or heating duration) through the power adjustment unit in that area to optimize the penetration depth of the electromagnetic field and promote core heating by utilizing the thermal conduction effect, thereby rapidly reducing the temperature gradient between the core and the surface, and thus making the radial heat penetration of the square steel uniform.

[0015] Compared with the existing technology that uses high-energy-consuming water curtains for forced cooling, the square steel induction heating device disclosed in this invention can suppress temperature difference from the source of heat generation, achieve uniform heating without the need for subsequent forced cooling, and prevent energy loss caused by overheating and subsequent cooling. On the other hand, it can significantly reduce operating costs, eliminating the need to maintain a complex water circulation system and treat wastewater.

[0016] Other features and advantages of this disclosure will be described in detail in the following detailed description section. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the present disclosure and form part of the specification. They are used together with the following detailed description to explain the present disclosure, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the structure of a square steel induction heating device provided in an exemplary embodiment of this disclosure; Figure 2 This is a cross-sectional schematic diagram of a square steel induction heating device provided in an exemplary embodiment of this disclosure; Figure 3 This is a core temperature curve provided by an exemplary embodiment of the present disclosure.

[0018] In the figure: 10, induction coil group; 11, induction coil; 20, square steel; 30, ring magnetic field adjustment mechanism; 31, magnetic field shielding sheet; 40, coil fixing assembly; 41, support base; 42, positioning flange; 50, furnace shell; 60, core temperature; 70, surface temperature. Detailed Implementation

[0019] The specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.

[0020] In the description of this disclosure, it should be understood that the terms "upper," "lower," etc., indicate the orientation or positional relationship based on... Figure 1 The orientations shown in the drawings are defined solely for the convenience of describing this disclosure and for simplification, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or a specific orientation construction and operation. Therefore, they should not be construed as limitations on this disclosure. Furthermore, the terms "inner" and "outer" refer to the inner and outer contours of the corresponding structures. In addition, the terms "first," "second," etc., are only used to distinguish one element from another and do not have any sequential or importance.

[0021] In the description of this disclosure, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "connect," "link," and "install" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0022] like Figures 1 to 3 As shown, this disclosure provides a multi-field coupling optimized square steel induction heating device, including an induction coil group 10, a power adjustment component, a temperature control monitoring module, and a control unit. The induction coil group 10 is used to sleeve on the square steel 20, and the induction coil group 10 includes multiple induction coils 11, which can be arranged at intervals along the axial direction of the square steel 20. The power adjustment component includes multiple power adjustment units, the number of which corresponds one-to-one with the number of induction coils 11, and each power adjustment unit is electrically connected to the corresponding induction coil 11. The temperature control monitoring module includes multiple sensor groups, the number of which corresponds one-to-one with the number of induction coils 11, and each sensor group is used to monitor the core-surface temperature difference and circumferential temperature difference of the corresponding part of the square steel 20 during the heating process. The control unit is electrically connected to the temperature control monitoring module and the power adjustment component, and is used to adjust the core-surface temperature difference and circumferential temperature difference of the corresponding part of the square steel 20.

[0023] It should be noted that the square steel 20 to be heated is 154 square steel from the 155mm shell punching line.

[0024] Among them, such as Figure 3 As shown, the core-surface temperature difference refers to the difference between the temperature at the center of the square steel 20 cross section (core temperature 60°C) and the temperature on the surface of the square steel 20 (surface temperature 70°C).

[0025] Through the above technical solution, the induction coil group 10, power adjustment component, temperature control monitoring module, and control unit enable precise heating control of the heating area of ​​the square steel 20 using multiple induction coils 11. Furthermore, multiple sensor groups can be used to monitor the core-to-surface temperature difference (the difference between the center temperature and surface temperature of the square steel 20 cross-section) and the circumferential temperature difference (the temperature difference between different circumferential positions of the square steel 20 cross-section, especially between sharp corners and edges) of each independent heating section in real time. Simultaneously, multiple power adjustment units can be used to adjust the energy input of each independent heating section as needed. Therefore, the control unit can dynamically calculate and generate independent power adjustment commands for each area based on the real-time core-to-surface and circumferential temperature difference data monitored by the temperature control monitoring module, combined with a preset multi-physics coupling optimization model, and then independently drive the corresponding power adjustment unit to adjust the input power of each induction coil 11. Specifically, when a large circumferential temperature difference is detected in a certain section (such as the temperature of the sharp corner being significantly higher than that of the edge), the control unit can reduce the coil power in that area to weaken the skin effect, thereby suppressing overheating of the sharp corner and balancing the circumferential temperature of the square steel 20. When a core-to-surface temperature difference is detected in a certain section, the control unit can control the electromagnetic parameters of the induction coil 11 (such as heating power density, current frequency, or heating duration) through the power adjustment unit in that area to optimize the penetration depth of the electromagnetic field and promote the heating of the core by utilizing the thermal conduction effect, thereby quickly reducing the temperature gradient between the core and the surface, and thus making the radial heat penetration of the square steel 20 uniform.

[0026] Compared with the existing technology that uses high-energy-consuming water curtains for forced cooling, the square steel induction heating device disclosed in this invention can suppress temperature difference from the source of heat generation, achieve uniform heating without the need for subsequent forced cooling, and prevent energy loss caused by overheating and subsequent cooling. On the other hand, it can significantly reduce operating costs, eliminating the need to maintain a complex water circulation system and treat wastewater.

[0027] In induction heating of square steel 20, due to the sharp-angle effect of the electromagnetic field, the current density and heating rate at the sharp corners are much higher than those at the center of the face. Therefore, as an implementation method, such as... Figures 1 to 2 As shown, each sensor group includes multiple temperature sensors, which can be arranged at circumferential intervals along the square steel 20.

[0028] By arranging temperature sensors at multiple points around the circumference, the system can calculate in real time the difference between the highest temperature (sharp corner) and the lowest temperature (edge) on the same cross-section. Once the control unit detects that this difference exceeds the limit, it can immediately instruct the power regulation unit in the corresponding area to reduce power or adjust the frequency, suppressing overheating at the sharp corner from the source, thereby ensuring uniform circumferential temperature of the 20mm square steel cross-section. In this way, precise quantification and real-time closed-loop control of the circumferential temperature difference can be achieved.

[0029] Alternatively, the temperature sensor may be a multispectral infrared array, an ultrasonic transducer array, or a fiber optic grating sensor, and this disclosure does not impose any limitations on it.

[0030] Optionally, the induction coil 11 is constructed as a copper hollow tube structure, and the surface of the induction coil 11 is coated with an insulating and high-temperature resistant coating.

[0031] Because induction heating has an extremely high power density, the induction coil 11 itself also generates a large amount of heat. Therefore, the hollow design allows cooling water to flow directly and at high speed inside the induction coil 11. In this way, the water flow inside the induction coil 11 prevents the coil from melting or deforming.

[0032] Optionally, the output power of the power regulation unit is 0-1500kW, and the response speed of the power regulation unit is ≤0.5s.

[0033] As one implementation method, such as Figures 1 to 2 As shown, the square steel induction heating device also includes an annular magnetic field adjustment mechanism 30, which is sleeved on the induction coil group 10. The annular magnetic field adjustment mechanism 30 includes multiple magnetic field shielding plates 31, which are arranged at intervals along the circumference of the induction coil group 10.

[0034] By using the ring magnetic field adjustment mechanism 30, the magnetic flux concentrated at the sharp corners of the square steel 20 can be selectively diverted and weakened, thereby effectively suppressing the sharp corner effect and achieving uniform heating temperature of the square steel 20 in the circumferential direction.

[0035] As one implementation method, such as Figures 1 to 2 As shown, the magnetic field shielding sheet 31 is constructed as an arc-shaped plate structure.

[0036] Since the induction coil 11 itself is arranged in a ring, the curvature of the arc-shaped plate structure can be designed to match the outer circumference of the induction coil 11. Furthermore, since magnetic field lines tend to close along the path of least magnetic resistance in a high-frequency alternating magnetic field, the arc-shaped structure can more naturally conform to the curvature of the magnetic field lines, avoiding magnetic flux distortion or local eddy current losses that may be caused by right-angled or planar structures, allowing the magnetic field lines to smoothly pass through the shielding sheet to form a shunt loop.

[0037] Optionally, the magnetic field shielding sheet 31 is made of a high-permeability alloy material, such as permalloy, nanocrystalline alloy, high-grade oriented silicon steel sheet, etc.

[0038] Optionally, the number of magnetic field shielding plates 31 can be at least 4, evenly distributed along the circumference, to meet the magnetic field optimization requirements of the four corners of the steel 20.

[0039] As one implementation method, such as Figures 1 to 2 As shown, the square steel induction heating device also includes a coil fixing assembly 40, which includes a support base 41, a positioning flange 42, and a locking component. Positioning flanges 42 are respectively fitted onto both ends of the induction coil assembly 10, and each positioning flange 42 is connected to the support base 41 on the furnace shell via a locking component. This arrangement prevents the induction coil assembly 10 from shifting axially (i.e., in the direction of travel of the square steel 20), thus ensuring that the relative position of the induction coil assembly 10 and the sharp corners and edges of the square steel 20 remains constant, guaranteeing the consistency of the heating process and preventing uneven heating or workpiece scratching caused by coil displacement.

[0040] like Figures 1 to 2 As shown, this disclosure also provides a method for induction heating of square steel 20, based on the above-mentioned square steel induction heating device, including the following steps: S1: Establish a multi-physics heating model for the square steel 20 to be heated, input the material parameters, size parameters and target temperature parameters of the square steel 20, simulate the temperature change curves of the core and surface of the square steel 20 under different power distributions, and fit to obtain the initial power ratio parameters of the multi-section induction coil group 10 so that the core-surface temperature difference of the square steel 20 is controlled within the preset range during the initial heating stage. S2: Based on the Maxwell equation finite element algorithm, simulate the magnetic field distribution under the sharp corner effect of square steel 20, determine the number and position of magnetic field shielding plates 31 and the spacing between adjacent induction coils 11 in the annular magnetic field adjustment mechanism 30, so as to balance the magnetic field distribution in the circumferential direction. S3: The square steel 20 to be heated is inserted into the induction coil group 10 and positioned and fixed by the coil fixing assembly 40; S4: Start each power regulation unit and output power according to the initial power ratio parameters; S5: During the heating process, the temperature control monitoring module is activated to collect the core surface temperature difference data and circumferential temperature difference data of the corresponding area of ​​the square steel 20 in real time through each sensor group, and transmit them to the control unit; S6: The control unit calculates the required compensation power for each area based on the monitoring data of each area and the preset target temperature curve, and adjusts the output power of the corresponding power adjustment unit until the overall temperature of the square steel 20 reaches the processing requirements and the temperature difference of each area is stable within the set range, so as to complete the heating process. S7: Turn off all power adjustment units and remove square steel 20 for subsequent processing.

[0041] Optionally, in S1, the preset range is ≤15℃ for the absolute value of the core-to-surface temperature difference; In S6, the set range includes: the absolute value of the core-surface temperature difference on the cross-section of square steel 20 is ≤15℃, and the absolute value of the circumferential temperature difference at the edge of the cross-section of square steel 20 is ≤20℃. The required processing temperature range is 1000-1170℃.

[0042] The preferred embodiments of this disclosure have been described in detail above with reference to the accompanying drawings. However, this disclosure is not limited to the specific details of the above embodiments. Within the scope of the technical concept of this disclosure, various simple modifications can be made to the technical solutions of this disclosure, and these simple modifications all fall within the protection scope of this disclosure.

[0043] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, this disclosure will not describe the various possible combinations separately.

[0044] Furthermore, various different embodiments of this disclosure can be combined in any way, as long as they do not violate the spirit of this disclosure, they should also be regarded as the content disclosed in this disclosure.

Claims

1. A multi-field coupling optimized induction heating device for square steel, characterized in that, Includes an induction coil assembly (10), a power regulation component, a temperature control monitoring module, and a control unit; The induction coil group (10) is used to be sleeved on the square steel (20). The induction coil group (10) includes a plurality of induction coils (11), and the plurality of induction coils (11) can be arranged at intervals along the axial direction of the square steel (20). The power adjustment assembly includes multiple power adjustment units, the number of which corresponds one-to-one with the number of induction coils (11), and each power adjustment unit is electrically connected to the corresponding induction coil (11); The temperature control monitoring module includes multiple sensor groups, the number of which corresponds one-to-one with the number of induction coils (11). Each sensor group is used to monitor the core surface temperature difference and circumferential temperature difference of the corresponding part of the square steel (20) during the heating process. The control unit is electrically connected to the temperature control monitoring module and the power adjustment component, and is used to adjust the core surface temperature difference and circumferential temperature difference of the corresponding part of the square steel (20).

2. The square steel induction heating device according to claim 1, characterized in that, Each of the sensor groups includes multiple temperature sensors that are arranged at circumferential intervals along the square steel (20).

3. The square steel induction heating device according to claim 1, characterized in that, The induction coil (11) is constructed as a copper hollow tube, and the surface of the induction coil (11) is coated with an insulating and high-temperature resistant coating.

4. The square steel induction heating device according to claim 1, characterized in that, The output power of the power regulation unit is 0-1500kW, and the response speed of the power regulation unit is ≤0.5s.

5. The square steel induction heating device according to claim 1, characterized in that, The square steel induction heating device also includes an annular magnetic field adjustment mechanism (30). The annular magnetic field adjustment mechanism (30) is sleeved on the induction coil group (10). The annular magnetic field adjustment mechanism (30) includes a plurality of magnetic field shielding plates (31), which are arranged at intervals along the circumference of the induction coil group (10).

6. The square steel induction heating device according to claim 5, characterized in that, The magnetic field shielding sheet (31) is constructed as an arc-shaped plate structure.

7. The square steel induction heating device according to claim 1, characterized in that, The square steel induction heating device also includes a coil fixing assembly (40), which includes a support base (41), a positioning flange (42), and a locking component; The two ends of the induction coil group (10) are respectively fitted with the positioning flange (42), and each positioning flange (42) is connected to the support seat (41) on the furnace shell through the locking member.

8. A method for induction heating of square steel, characterized in that, The square steel induction heating device according to any one of claims 1-7 includes the following steps: S1: Establish a multi-physics heating model for the square steel (20) to be heated, input the material parameters, size parameters and target temperature parameters of the square steel (20), simulate the temperature change curves of the core and surface of the square steel (20) under different power distributions, and fit to obtain the initial power ratio parameters of the multi-section induction coil group (10) so that the core-surface temperature difference of the square steel (20) is controlled within the preset range during the initial heating stage; S2: Based on the Maxwell equation finite element algorithm, simulate the magnetic field distribution under the sharp corner effect of square steel (20), determine the number and position of magnetic field shielding plates (31) and the spacing between adjacent induction coils (11) in the ring magnetic field adjustment mechanism (30) to balance the magnetic field distribution in the circumferential direction; S3: The square steel (20) to be heated is inserted into the induction coil group (10) and positioned and fixed by the coil fixing assembly (40); S4: Start each of the power regulation units and output power according to the initial power ratio parameters; S5: During the heating process, the temperature control monitoring module is activated, and the core surface temperature difference data and circumferential temperature difference data of the corresponding area of ​​the square steel (20) are collected in real time through each of the sensor groups and transmitted to the control unit; S6: The control unit calculates the compensation power required for each area based on the monitoring data of each area and the preset target temperature curve, and adjusts the output power of the corresponding power adjustment unit until the overall temperature of the square steel (20) reaches the processing requirements and the temperature difference of each area is stable within the set range, so as to complete the heating process. S7: Turn off each of the power adjustment units and take out the square steel (20) to proceed to the subsequent processing steps.

9. The induction heating method for square steel according to claim 8, characterized in that, In S1, the preset range is that the absolute value of the core-to-surface temperature difference is ≤15℃; In S6, the set range includes: the absolute value of the core-surface temperature difference on the cross-section of the square steel (20) is ≤15℃, and the absolute value of the circumferential temperature difference at the edge of the cross-section of the square steel (20) is ≤20℃; The required processing temperature range is 1000-1170℃.

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