A hub magnetic flux leakage power generation and high-frequency auxiliary heating integrated heat preservation device and a regulation and control method thereof

Abstract

A wheel hub magnetic flux leakage power generation and high-frequency auxiliary heating integrated heat preservation device and its regulation method belong to the field of aluminum alloy wheel hub preheating equipment. The device replaces the traditional heat shield and contains an annular protective frame, a high-magnetic-resistance magnetic insulation heat insulation composite interlayer, and a 12-segment segmented water-cooled multipurpose coil array. A permanent magnet disc, a wheel hub, an air gap, a heat insulation composite interlayer, and a multipurpose coil are sequentially arranged from the inside to the outside along the radial direction. The coil can work in time: in the heating stage, the magnetic flux leakage power generation energy is recovered; in the middle and late heating stage, the high-frequency coil is switched to assist in heating the outer wall of the wheel hub. The coil is configured with a series-parallel electric control switching module to adaptively compensate for the magnetic flux decay under different air gaps; an electric energy scheduling logic is set: the energy storage electric energy is preferentially supplied to the high-frequency heating load, and the surplus electric energy compensates for the disc driving motor. The interlayer is built-in silicon steel laminated to block the high-frequency magnetic field and prevent the permanent magnet from demagnetizing; the coil terminals are concentrated on the outside for easy maintenance. The present application realizes energy recovery and consumption reduction and is suitable for preheating production of aluminum alloy wheel hubs of multiple specifications.

Description

Technical Field

[0001] This invention belongs to the technical field of preheating equipment for aluminum alloy wheel hub spinning of new energy vehicles. Specifically, it involves a wheel hub fixing and a thermal insulation and protection structure for a permanent magnet disk rotary eddy current heating device. In particular, it involves an integrated ring device and a supporting coordinated control method that can realize leakage magnetic field recovery and power generation, high-frequency auxiliary heating of the outer wall of the wheel hub, sequential supply of recovered electrical energy to the high-frequency heating load, and compensation of the power consumption of the disk drive motor with surplus electrical energy. Background Technology

[0002] Before the aluminum alloy wheel hubs for new energy vehicles are spun and formed, the wheel hub blanks need to be preheated uniformly to 420℃~450℃ to ensure uniform metal structure and stable forming. Currently, new processing equipment in the industry is gradually adopting permanent magnet disk rotary eddy current heating technology. This technology differs from traditional external heat source baking methods. Its working principle is as follows: a high-speed rotating permanent magnet magnetic field penetrates the wheel hub metal substrate, generating eddy currents and self-generating heat within the overall wall thickness of the wheel hub. This is a self-heating method for the entire workpiece, offering advantages such as uniform heating, high thermal efficiency, and no open flame pollution.

[0003] Currently, the external protection system of permanent magnet eddy current hub heating equipment on the market all uses a closed metal sheet heat insulation cover as the only insulation, heat insulation and safety protection structure. The structure and function are single and have several inherent technical defects under industrial continuous mass production conditions: First, traditional metal heat shields have limited heat insulation performance. During the self-heating process of the wheel hub, the outer surface of the hub directly forms high-intensity convection heat dissipation with the air inside the shield, and heat from the surface of the workpiece continues to escape. To maintain the constant temperature range of the process, the equipment needs to continuously maintain a high-power magnetic field output to compensate for heat loss, resulting in high overall ineffective energy consumption and poor energy efficiency.

[0004] Secondly, conventional metal heat insulation covers are pure sheet metal rigid structures, which only have physical enclosure and passive heat preservation functions. They lack any magnetic field optimization, thermal field compensation, and energy regulation structures, resulting in extremely low functional integration, redundant equipment structure, complex parts, and high assembly and maintenance costs.

[0005] Third, permanent magnet disks require model replacement to match hubs of different diameters and specifications, resulting in significant variations in the installation distance between the permanent magnet working magnetic field and the outer protective structure of the equipment. Traditional fixed heat shield structures are standardized and cannot adapt to the thermal field adaptation and magnetic field optimization requirements under variable spacing conditions, making it difficult to unify the heating process for hubs of different specifications.

[0006] Fourth, when a metal heat shield is in a diffuse alternating magnetic field environment, the metal sheet of the shield will be induced by the magnetic field to generate ineffective parasitic eddy currents, which will continuously generate useless heat loss, further increasing the energy consumption of the equipment. At the same time, it will cause the shield to accumulate heat at high temperatures for a long time, deform and age, and reduce the overall service life and operational stability of the equipment.

[0007] In summary, current permanent magnet eddy current hub heating equipment relies solely on traditional metal heat shields for basic protection and insulation. This results in a limited structural functionality, high ineffective energy consumption, and a lack of energy recovery capabilities. The industry currently lacks a novel, integrated protective structure that can replace traditional heat shields and combine efficient insulation, magnetic field shielding, thermal field compensation, leakage magnetic energy recovery, and graded energy scheduling (prioritizing high-frequency heating and using surplus energy to compensate for the drive motor). This presents a clear opportunity for technological improvement and represents a significant technological gap in the industry. Summary of the Invention

[0008] Purpose of the invention In view of the technical defects of existing permanent magnet eddy current hub heating equipment, such as single function of the outer protective structure, large heat loss, high ineffective eddy current loss, poor adaptability to working conditions, no thermal field compensation capability, low equipment integration, inability to recover and utilize leakage magnetic energy, and lack of power priority scheduling strategy, this invention provides a hub leakage magnetic power generation and high frequency auxiliary heating integrated heat preservation device and its control method.

[0009] This invention completely eliminates the traditional metal heat shield, replacing the original protective structure with a segmented water-cooled reusable coil structure. It simultaneously achieves multiple functions including equipment insulation enclosure, leakage magnetic energy recovery, and high-frequency thermal compensation for the outer wall of the hub. The addition of a magnetic and thermal insulation composite interlayer solves the problems of high-frequency magnetic field demagnetization and high-temperature radiation aging. Through a coil series-parallel electronic control switching topology, it adaptively compensates for power generation attenuation under different air gaps. A collaborative control strategy is designed to prioritize the supply of leakage magnetic energy to the high-frequency auxiliary heating load, with the remaining surplus energy then compensating for the power consumption of the main disk rotating motor. Relying on time-sharing interlock control logic, it balances equipment energy saving and efficiency improvement with the stability of the hub heating process, addressing the industry shortcomings of existing equipment such as structural redundancy, high energy consumption, weak adaptability, and lack of energy recovery functionality.

[0010] Technical solution The integrated device of the present invention mainly consists of a ring-shaped protective frame, a multi-layer composite heat insulation liner, a high magnetic resistance magnetic heat insulation composite sandwich layer, a segmented water-cooled multiplexed coil array, a high magnetic resistance isolation strip, a dual-circuit interlocking switching module, a rectifier energy storage module, a high-frequency inverter heating power supply, a temperature control energy consumption control unit, a coil series-parallel electronic control switching module, and a hub temperature detection component.

[0011] The annular protective frame coaxially surrounds the outer circumference of the stationary aluminum alloy hub, replacing the original sealed heat insulation cover and hot air auxiliary heating cavity of the equipment. Arranged radially from the center outwards are: main unit rotating permanent magnet disk, fixed aluminum alloy hub, 20mm safety air gap, high magnetic barrier magnetic heat insulation composite sandwich layer, polyimide insulation pad layer, and segmented water-cooled multiplexed coil array.

[0012] The high magnetic barrier magnetic insulation composite sandwich is made of non-magnetic stainless steel sheet and nano-aerogel insulation layer pressed together; from the inside to the outside along the radial direction, there are non-magnetic stainless steel sheet and nano-aerogel insulation layer; the nano-aerogel insulation layer is attached to the side of non-magnetic stainless steel sheet facing the wheel hub; on the side of nano-aerogel insulation layer away from the wheel hub, there are axially stacked cold-rolled silicon steel laminate magnetic collecting sheets; the plane of the cold-rolled silicon steel sheets is arranged along the radial direction of the wheel hub and the stacking direction is parallel to the wheel hub axis, and the effective radial width of the silicon steel laminate is set to 20mm~40mm; a polyimide insulating pad is laid on the outside of the silicon steel laminate.

[0013] The cold-rolled silicon steel laminated magnetic collecting sheet is mainly used to block the high-frequency alternating magnetic field generated by the segmented water-cooled multiplexed coil from propagating inward, preventing the high-frequency magnetic field from passing through the interlayer, air gap and hub, interfering with the inner permanent magnet disk, and preventing the permanent magnet disk from generating eddy current heating and causing demagnetization; the nano aerogel heat insulation layer, together with the non-magnetic stainless steel sheet, isolates the hub from the high temperature of 420℃~450℃ radiating outward, reducing the heat load on the outer silicon steel laminate and water-cooled coil.

[0014] The segmented water-cooled reusable coil array consists of 12 independent arc-shaped hollow T2 copper coils evenly arranged circumferentially, with a central angle of 30° for each coil segment. The coils are integrally cold-bent from rectangular hollow copper tubes, with cooling water channels running through the inside of the tubes. Each coil segment is wound with 3 turns in a single layer of concentric arcs, with a 0.5mm gap between turns. The insulation gaps are filled with high-temperature resistant thermally conductive epoxy resin; each coil segment is double-layered with polyimide high-temperature insulation tape and mica composite insulation sleeve, with high-temperature resistant thermally conductive epoxy resin filling the gaps between the layers; high magnetic resistance isolation strips made of austenitic stainless steel are set between adjacent arc-shaped coils; each high magnetic resistance isolation strip is independent of each other and not connected circumferentially, and the two ends of the isolation strip are insulated and fixed to the ring-shaped protective frame. A gap is reserved between the isolation strip and the rectangular coil, and a 1mm thick polyimide insulation pad is attached to both sides to avoid forming a continuous closed metal conductor ring and to prevent the alternating magnetic field from exciting ring-shaped eddy current losses; the silver-plated bus terminals and water-cooling inlet and outlet ports of each coil segment are uniformly arranged on the outer side above the coil, away from the high-temperature radiation area of ​​the hub, realizing the centralized external arrangement of water and electricity terminals, which facilitates wiring, pipeline assembly and later maintenance; the entire coil can realize two working modes: leakage magnetic induction power generation and high-frequency eddy current auxiliary heating at different times.

[0015] The coil series-parallel electronic control switching module is electrically connected to the silver-plated bus terminal on the outer side of the 12-segment segmented water-cooled multiplexed coil, supporting both full parallel and series-parallel combination wiring modes. Under normal operating conditions with a 50mm working air gap between the permanent magnet disk and the coil, it switches to full parallel wiring. When the air gap between the permanent magnet disk and the coil expands to 90mm and power generation is weak, it switches to series-parallel combination wiring, effectively increasing the total number of turns in the induction winding and compensating for flux attenuation caused by leakage flux passing through multiple layers of media. During high-frequency auxiliary heating operation, the coil is forced to switch to full parallel wiring mode to minimize the total coil inductance, adapting to the resonant matching of the high-frequency inverter power supply.

[0016] The dual-circuit interlocking switching module is electrically connected to the coil series-parallel electronic control switching module, the rectifier energy storage module, and the high-frequency inverter heating power supply. The module has a built-in electronic relay electrical interlocking structure, which ensures that only one circuit is activated at any given time, preventing short circuits and magnetic field collisions caused by simultaneous activation of the power generation and heating circuits.

[0017] The temperature control and energy consumption control unit is connected to the hub temperature detection component, the dual-loop interlock switching module, the rectifier energy storage module, the high-frequency inverter heating power supply, the coil series-parallel electronic control switching module, and the permanent magnet disk main servo motor driver. Based on the real-time hub temperature and the real-time working air gap between the permanent magnet disk and the coil, it automatically switches the coil wiring mode and the coil working circuit. The rectifier energy storage module has power scheduling logic: the recovered power is given priority to the high-frequency inverter heating power supply. After meeting the high-frequency heating power requirements, the surplus power is output to compensate for the power consumption of the permanent magnet disk main servo motor.

[0018] The segmented water-cooled multiplexed coil is internally cooled by a 1.2MPa industrial chiller-supplied soft water circulation system, ensuring the coil's long-term steady-state operating temperature remains below 100℃. Each segment of the coil has an independent inlet and outlet on its outer surface, and all segmented cooling water circuits are connected in parallel to a water distributor for unified water supply. A multi-layer composite insulation liner with a total thickness of 1.5–3mm is attached to the sides and bottom of the rectangular coil and the annular protective frame. The rectifier energy storage module integrates a supercapacitor and a lithium battery pack to smooth power generation fluctuations and stores electrical energy during power generation. Under high-frequency heating conditions, electrical energy is prioritized for the high-frequency inverter heating power supply, with the remaining energy used to compensate the main servo motor. When there is no high-frequency heating requirement, the stored energy directly compensates for the power consumption of the permanent magnet disk main servo motor.

[0019] The annular protective frame is integrally molded from glass fiber reinforced high-temperature resistant PA66 non-magnetic plastic. An arc-shaped groove is provided on the inner side of the frame for limiting and fixing the segmented water-cooled reusable coils. Multiple layers of composite heat insulation lining are adhered to the inner wall of the groove. Each segmented arc-shaped coil is wound with 3 turns per layer, and the copper tube specifications and number of turns are consistent across all segmented coils. The entire coil system passed a 5kV withstand voltage test for 1 minute without breakdown, and the water-cooling circuit withstood a 1.2MPa pressure for 30 minutes without leakage. The coil series-parallel electrical control switching module is controlled by an MCU control unit, which can automatically switch the wiring topology according to the working air gap value after the permanent magnet disk specification is changed.

[0020] The alternating magnetic field generated by the rotation of the permanent magnet disk first penetrates the aluminum alloy hub. Part of the leakage magnetic field passes outward through a 20mm safety air gap, a non-magnetic stainless steel sheet, and a nano-aerogel insulation layer to reach the outer segmented water-cooled reuse coil to achieve energy recovery. The leakage magnetic field attenuates as it passes through multiple layers of media. This device uses a coil series-parallel electronic control switching module to adjust the coil wiring method to increase the equivalent winding turns under conditions of increased distance between the disk and the coil and decreased power generation, forming a two-series-six-parallel connection to compensate for the induced electromotive force and ensure the energy recovery effect.

[0021] This invention provides a method for coordinated control of leakage magnetic field power generation, high-frequency auxiliary heating, and residual power compensation of the main disk rotary motor, which is implemented according to the following steps: S0, Power-on self-test and parameter initialization Upon system power-up, the system completes hardware self-tests for the temperature acquisition module, hub specification encoder, dual-circuit interlock switching module, coil series-parallel switching module, energy storage management unit, and main servo driver. The hub specification encoder acquires the real-time air gap between the permanent magnet disk and the segmented water-cooled multiplexed coil. Based on the air gap, the initial coil wiring mode is set: 50mm~70mm air gap, default full parallel connection; 71mm~90mm air gap, switch to series-parallel combination mode. The system reads the rectifier energy storage module's power level and sets the upper limit of energy storage to 90% and the lower limit to 30%. The main servo motor and high-frequency inverter power supply are locked in standby mode.

[0022] S1, Heating Start-up Stage (Wheel Hub Temperature < 380℃, Early Stage of Heating) The temperature control and energy consumption control unit issues commands, the dual-loop interlock module connects the power generation circuit and disconnects the high-frequency heating circuit; the main servo motor is started, driving the permanent magnet disk to rotate at a constant speed of 800-1200 r / min, and the alternating magnetic field heats the stationary hub body with eddy currents; the multiplexed coil captures leakage flux to generate alternating current, which is rectified and regulated and sent to the rectifier energy storage module to store energy in the storage battery pack; during this stage, there is no high-frequency heating load requirement, and the energy storage module outputs power to directly compensate for the real-time power consumption of the main servo motor, with the grid only supplementing the power difference; the hub temperature is continuously collected and the cyclic temperature is determined; when the air gap changes, the system adaptively switches the coil series-parallel topology to stabilize the power generation output.

[0023] S2, Temperature rise transition judgment node (wheel hub temperature reaches 380℃) The system triggers an interlocking switching signal; the coil series-parallel control switching module forces the 12 coil segments to switch to full parallel mode, reducing the coil inductance to match the high-frequency power supply; the dual-circuit interlocking module activates, disconnecting the generator rectifier circuit, and after a 500ms delay, connecting the high-frequency inverter heating power supply, releasing the residual induced electromotive force of the coil after a delay, and suppressing voltage surges.

[0024] S3, High-frequency auxiliary heating stage (380℃ ≤ wheel hub temperature < 420℃, mid-to-late stage of heating) A 20-50kHz high-frequency alternating current is passed through the multiplexed coil to generate a high-frequency alternating magnetic field to assist in eddy current heating of the outer wall of the wheel hub; the rectifier energy storage module releases stored electrical energy and prioritizes supplying it to the high-frequency inverter heating power supply; if the energy storage output meets the full power demand of high-frequency heating and there is still a surplus, the surplus electrical energy is then output to compensate for the power consumption of the main servo motor; the wheel hub temperature is continuously monitored until the temperature reaches 420℃ and enters the constant temperature heat preservation cycle; during this stage, the coil stops generating electricity through leakage magnetic flux, and the energy storage unit only discharges and does not charge.

[0025] S4. Constant temperature insulation stage (the wheel hub is stably maintained in the process range of 420℃~450℃, with intermittent rotation control every 20 seconds). Sub-step A (first 10 seconds of the cycle: high-frequency heating mode): Keep the high-frequency inverter circuit on, with all coils running in parallel to compensate for heat loss from the outer wall of the hub; the energy storage module releases electrical energy to prioritize supplying the high-frequency inverter power supply. If the electrical energy is sufficient, the remaining electrical energy compensates for the power consumption of the main servo motor and does not generate electricity.

[0026] Sub-step B (10s after cycle: leakage magnetic generation mode): Cut off the high-frequency inverter power supply and switch to the generation circuit; select the coil series-parallel mode to recover leakage magnetic energy according to the real-time air gap; store the electrical energy in the energy storage module; there is no high-frequency load, and the stored electrical energy is used first to compensate for the power consumption of the main servo motor; when the stored energy reaches 90% of the upper limit, the overcharge discharge protection is activated.

[0027] Repeatedly execute sub-steps A and B; if the hub temperature is >450℃, extend the power generation time and shorten the high-frequency heating time; if the hub temperature is <420℃, increase the high-frequency heating duty cycle.

[0028] S5, Production Shutdown Procedure Upon receiving the shutdown command, the high-frequency inverter heating power supply is first cut off; after a 20-second delay, the power generation mode is maintained, relying on the remaining rotating magnetic field of the permanent magnet disk to continuously recover leakage magnetic energy; after the delay ends, the power generation circuit is disconnected; the speed of the main servo motor is gradually reduced until the machine stops; the water cooling system runs continuously for 10 minutes to force cooling of the multiplexed coil, and the whole machine enters standby mode.

[0029] S6, Full-process embedded exception collaborative protection logic If the coil temperature exceeds 120℃, immediately cut off the high-frequency power supply, switch to the power generation mode, and increase the cooling water flow; if the energy storage capacity is less than 30%, the power generation mode will only charge and stop supplying power to the outside, and the high-frequency mode will limit the output power; if an interlock failure is detected and the power generation and heating circuits are simultaneously connected, the system will shut down urgently and issue an audible and visual alarm; if the hub temperature exceeds 460℃, all heating functions will be locked, and only the power generation and cooling modes will be retained.

[0030] Beneficial effects 1. The overall structure is highly integrated, completely replacing the traditional heat shield structure. This invention eliminates the traditional metal sheet heat insulation cover and hot air insulation system, and uses a segmented water-cooled multiplexed coil array as the core protective body on the outside of the whole machine. It simultaneously realizes multiple functions such as enclosure protection, heat insulation, leakage magnetic power generation, and high-frequency heat replenishment of the outer wall, which greatly reduces the number of parts of the whole machine, simplifies the equipment assembly structure, and eliminates the problems of parasitic eddy current loss and high temperature deformation of traditional metal covers.

[0031] 2. Adaptive to various wheel hub specifications and variable air clearance conditions By switching the coil series-parallel electronic control topology, the equipment can automatically adjust the number of equivalent winding turns according to the large range of air gap changes from 50mm to 90mm after the permanent magnet disk specification is changed. This compensates for the power generation attenuation problem caused by leakage magnetic penetration of the multi-layer structure, so that the heating of different specifications of wheel hubs can maintain a stable energy recovery capability and significantly improve the process adaptability.

[0032] 3. Rationally allocate and recover electrical energy, prioritize heating process requirements, and maximize energy-saving benefits. This device can capture the naturally dissipated leakage magnetic field during permanent magnet heating and convert it into electrical energy for storage. It innovatively prioritizes energy usage: when high-frequency heating is required, the recovered energy is prioritized for supplying the high-frequency inverter heating system to ensure the wheel hub heating process; if there is still surplus energy after supplying the high-frequency load, it is then used to compensate for the power consumption of the permanent magnet disk drive servo motor. Prioritizing the stability of the workpiece heating process while maximizing the utilization of recovered energy to reduce grid load aligns with the energy-saving technological transformation needs of intelligent manufacturing.

[0033] 4. Improve the constant temperature stability of the wheel hub and reduce heat dissipation fluctuations on the outer wall. By using high-frequency eddy current heating in the mid-to-late stages, the continuous convective heat loss of the outer wall of the wheel hub is accurately compensated, the temperature consistency in the constant temperature range is stabilized, the heat dissipation differences caused by different wheel hub specifications and different working air gaps are weakened, and the consistency of the spun product is improved.

[0034] 5. Reliably blocks high-frequency magnetic fields, preventing permanent magnet disks from demagnetizing. The silicon steel laminate is arranged inside the coil, which effectively blocks the high-frequency alternating magnetic field generated by the coil from penetrating inward, and avoids the high-frequency magnetic field from acting on the permanent magnet disk to generate eddy current heating and permanent magnet demagnetization; at the same time, the nano aerogel heat insulation layer effectively blocks the high temperature of the hub from being transmitted outward, protecting the silicon steel laminate and the coil to work stably for a long time.

[0035] 6. Easy to assemble and maintain, suitable for continuous industrial production. All electrical terminals and water-cooling interfaces of the coil are centrally located on the upper outer side, eliminating the need to disassemble the inner heat insulation structure for assembly wiring, water pipe connection, and later maintenance, and providing ample operating space; at the same time, it avoids the defect of rapid aging of wiring insulation caused by high temperature radiation.

[0036] 7. Fully automated time-sharing coordinated control enables multi-level energy scheduling. This invention constructs an integrated collaborative control scheme for leakage magnetic field power generation, high-frequency auxiliary heating, and residual power compensation main drive motor. It sets the priority of electrical load, automatically matches the coil wiring method and working mode according to the wheel hub heating stage, real-time temperature, and working air gap, and intelligently schedules the recovery of electrical energy, taking into account both energy saving effect and wheel hub heating process quality, and is suitable for 24-hour continuous mass production conditions. Attached Figure Description

[0037] Figure 1 is a schematic diagram of the overall assembly axial cross-sectional structure of the present invention; Figure 2 is a schematic diagram of the circumferential arrangement of the segmented water-cooled multiplexed coil array of the present invention; Figure 3 is a schematic diagram of the axial layered structure of the segmented water-cooled multiplexed coil of the present invention; Figure 4 is a schematic diagram of the layered structure of the high magnetic barrier magnetic thermal insulation composite sandwich of the present invention; Figure 5 is a block diagram of the electrical control circuit connection of the present invention; Explanation of reference numerals in the attached figures: 1- Annular protective frame; 2- Multi-layer composite thermal insulation liner; 3- High magnetic resistance magnetic thermal insulation composite interlayer; 301- Non-magnetic stainless steel sheet; 302- Nano-aerogel thermal insulation layer; 303- Cold-rolled silicon steel laminated magnetic collecting sheet; 4- Segmented water-cooled multiplexed coil array; 401- Hollow T2 copper tube; 402- Polyimide insulation layer; 403- Mica composite insulation sleeve; 404- Cooling water channel; 405- Silver-plated bus terminal; 5- High magnetic resistance isolation strip; 10- Hub temperature detection component; 11- Stationary aluminum alloy hub; 12- Inner rotating permanent magnet disk; 14- Water distributor; 16- Polyimide insulation pad layer; Detailed Implementation

[0038] This embodiment is equipped with a hub heating device with an outer diameter of Φ500mm and an inner diameter of Φ280mm. The hub is fixed throughout, and the inner rotating permanent magnet disk 12 has a rated operating speed of 1000r / min. The permanent magnet disk can be replaced with three sizes: 22-inch, 21-inch, and 20-inch hubs, corresponding to working air gaps of 50mm, 70mm, and 90mm for the permanent magnet disk-segmented water-cooled multiplexed coil, respectively.

[0039] Radial assembly sequence from center to outside: inner rotating permanent magnet disk 12 → stationary aluminum alloy hub 11 → 20mm safety air gap → high magnetic barrier magnetic heat insulation composite sandwich layer 3 → polyimide insulating pad layer 16 → segmented water-cooled multiplexed coil array.

[0040] The high magnetic barrier magnetic insulation composite sandwich layer 3 is formed by combining a 0.5mm non-magnetic stainless steel sheet 301 and a 1.5mm nano-aerogel insulation layer 302. The nano-aerogel insulation layer 302 is bonded to the non-magnetic stainless steel sheet 301 facing the wheel hub. A cold-rolled silicon steel laminated magnetic collecting sheet 303 with an effective radial width of 40mm is set on the outer side of the nano-aerogel insulation layer 302. Each silicon steel sheet is made of 0.35mm non-oriented cold-rolled silicon steel, with a total axial stacking thickness of 115mm, and inter-sheet insulation. A polyimide insulating pad 16 is laid on the outer side of the cold-rolled silicon steel laminated magnetic collecting sheet 303.

[0041] The segmented water-cooled multiplexed coil array 4 is divided into 12 independent arc-shaped coil units, each with a central angle of 30°. Adjacent coils are fitted with 6mm thick austenitic stainless steel high magnetic reluctance isolation strips 5. These 12 high magnetic reluctance isolation strips 5 are independent of each other, with both ends fixed to the annular protective frame 1 by insulating bolts. Gaps are reserved between the high magnetic reluctance isolation strips 5, and 1mm polyimide insulation sheets are laminated on both sides, ensuring no contact or communication between them. The coil conductors are rectangular hollow T2 copper tubes with outer dimensions of 16mm × 8mm and a wall thickness of 2mm. Cooling water channels are located inside the copper tubes. The outer layer of the copper tubes is first partially wrapped with a double layer of 0.3mm polyimide insulation, then covered with a 0.8mm mica composite insulating sleeve, and the interlayer is filled with high-temperature resistant, thermally conductive epoxy resin for curing. Each coil segment is wound with 3 turns in a single layer. Silver-plated bus terminals, water-cooling inlets, and outlets are led out from the outer side of each coil segment. All segmented coils are electrically connected to a coil series-parallel control switching module.

[0042] Each section of the coil is equipped with an independent inlet and outlet water nozzle, all located on the outer side above the coil. All sections of the cooling water circuit are connected in parallel to the water distributor, and 1.2MPa industrial refrigeration soft water is circulated for cooling. The steady-state temperature of the coil is stable at 75-100℃.

[0043] The coil series-parallel electronic control switching module is controlled by an MCU. For air gaps of 50mm and 70mm, all 12 coil segments are connected in parallel. For a 90mm air gap, a series-parallel combination connection is used, with two segments connected in series as a group and six groups connected in parallel, effectively increasing the total number of turns in the induction winding and compensating for leakage flux attenuation. The dual-circuit interlocking switching module adopts a dual-relay electrical interlocking structure. One circuit connects to the rectifier energy storage module integrating a supercapacitor and a lithium battery, while the other connects to a 20-50kHz high-frequency inverter heating power supply. The temperature control and energy consumption control unit collects signals from the wheel hub temperature detection component and the wheel hub specification encoder, automatically completing the circuit switching. The rectifier energy storage module is configured with energy scheduling logic: when there is a high-frequency heating demand, energy is prioritized for the high-frequency inverter power supply, and the remaining energy compensates the main servo motor; when there is no high-frequency load, it directly compensates for the servo motor power consumption.

[0044] Operational process of supporting coordinated control methods: S0. Power-on self-test of the equipment, actual air gap measurement of the hub specification encoder, switching of the coil to series-parallel combination mode under the condition of 90mm air gap; energy storage module power detection, parameter initialization; S1. The main servo motor drives the disk to rotate at a constant speed of 1000r / min. When the hub temperature is below 380℃, the equipment operates in power generation mode. The multiplexed coil captures leakage flux to generate electricity, which is stored in the energy storage module. There is no high-frequency load, and the stored energy first offsets the power consumption of the main servo motor. The hub temperature is continuously collected. S2. When the temperature rises to 380℃, the coil is forced to switch to full parallel mode, and after a delay of 500ms, it switches to high-frequency heating mode. S3, in the 380℃~420℃ range, the high-frequency inverter power supply works, and the coil generates a high-frequency magnetic field to assist in heating the outer wall of the hub; the stored and released electrical energy is given priority to the high-frequency inverter power supply, and the remaining electrical energy is used to compensate the main servo motor. S4. When the temperature stabilizes to 420℃~450℃, execute a 20s cycle: 10s high-frequency heat replenishment (electrical energy is prioritized for high-frequency loads), 10s leakage magnetic field power generation and energy storage to compensate the main servo motor; dynamically adjust the high and low frequency duty cycles according to the temperature. S5. Upon receiving the shutdown command, the high-frequency power supply is cut off, and leakage magnetic energy is continuously recovered after a 20-second delay. The main servo motor is then stopped. The water cooling system continues to run for 10 minutes to cool the coils. S6. The system monitors coil temperature, stored energy, and interlock status in real time throughout the process, and executes corresponding protection actions when triggering thresholds.

[0045] The entire machine underwent a continuous 8-hour no-load stable operation test: the uniform temperature error of the hub circumference was 2.5%, and the highest steady-state temperature of the coil was 93.5℃; the terminals were arranged on the upper outer side, and the insulation showed no aging during long-term operation; there were no permanent magnet demagnetization, coil insulation breakdown, or water leakage faults throughout the entire process; under the condition of a 90mm large gap, the power generation output voltage was stable by relying on series-parallel switching compensation; the silicon steel stack effectively blocked the transmission of high-frequency magnetic fields inward, and the permanent magnet disk did not exhibit abnormal heating or demagnetization; the generated and recovered electrical energy prioritized the high-frequency heating needs of the outer wall, and the surplus electrical energy offset the power consumption of the servo motor, resulting in a significant reduction in the overall power consumption of the machine.

[0046] Control group 1: Traditional metal heat shield + hot air insulation structure, without reused coil, without energy recovery, without high frequency heat replenishment function, the metal shield of the equipment has obvious parasitic eddy current loss, large heat loss on the outer wall, high energy consumption, and no operating condition self-adaptation capability.

[0047] Control group 2: Fixed fully parallel coil structure, no series-to-parallel switching function, large gap 90mm power generation significantly reduced under operating conditions, cannot be adapted to multi-specification hub equipment, and there is no hierarchical power dispatch strategy.

[0048] This invention replaces the traditional heat shield with an integrated coil structure, eliminating ineffective eddy current losses from the metal shield; the coil terminals and the outer side above the water inlet are arranged for easy maintenance and to delay insulation aging; independent segmented stainless steel isolation strips are used between adjacent coils to eliminate eddy current losses from closed metal rings; a directional, fixed-size axial silicon steel laminated shielding structure is used to prioritize blocking high-frequency magnetic fields and protect the permanent magnet disk; a collaborative control scheme with priority power scheduling is constructed, where generated power is prioritized for supplying high-frequency heating loads, and surplus power is used to compensate the main drive motor, providing adaptive power generation and voltage boosting, high-frequency thermal compensation, and time-sharing energy recovery capabilities, significantly reducing equipment energy consumption and greatly improving process adaptability and operational stability.

[0049] This invention is not limited to the specific embodiments described above. Those skilled in the art can make several modifications and alterations without departing from the technical concept of this invention, and all such modifications and alterations should be covered within the scope of protection of the claims of this invention.

Claims

1. A hub leakage magnetic power generation and high-frequency auxiliary heating integrated heat preservation device, adapted to a hub-fixed, inner permanent magnet disk rotating eddy current heating device, characterized in that: Includes a ring-shaped protective frame, a multi-layer composite thermal insulation liner, a high magnetic resistance magnetic thermal insulation composite interlayer, a segmented water-cooled multiplexed coil array, a high magnetic resistance isolation strip, a dual-circuit interlocking switching module, a rectifier energy storage module, a high-frequency inverter heating power supply, a temperature control energy consumption control unit, a coil series-parallel electronic control switching module, and a hub temperature detection component; Arranged radially from the center outwards as follows: inner rotating permanent magnet disk, stationary aluminum alloy hub, 20mm safety air gap, high magnetic barrier magnetic insulation composite sandwich layer, polyimide insulating pad layer, and segmented water-cooled multiplexed coil array; The high magnetic barrier magnetic insulation composite sandwich layer is made of non-magnetic stainless steel sheet and nano-aerogel insulation layer pressed together; from the inside to the outside along the radial direction, it consists of non-magnetic stainless steel sheet and nano-aerogel insulation layer; the nano-aerogel insulation layer is attached to the side of non-magnetic stainless steel sheet facing the wheel hub; on the side of nano-aerogel insulation layer away from the wheel hub, there is an axially stacked cold-rolled silicon steel laminate magnetic collecting sheet; the plane of the cold-rolled silicon steel sheet is arranged along the radial direction of the wheel hub and the stacking direction is parallel to the wheel hub axis, and the effective radial width of the silicon steel laminate is set to 20mm~40mm; a polyimide insulating pad is laid on the outside of the silicon steel laminate. The segmented water-cooled multiplexed coil array consists of 12 independent arc-shaped hollow T2 copper coils evenly arranged circumferentially, with a central angle of 30° for each coil segment. The coils are integrally cold-bent from rectangular hollow copper tubes, with cooling water channels inside the tubes. Each coil segment is wound with 3 turns in a single concentric arc. High magnetic reluctance isolation strips made of austenitic stainless steel are placed between adjacent arc-shaped coils. Each high magnetic reluctance isolation strip is independent of the others and not connected circumferentially. The isolation strips are insulated and fixed to the annular protective frame. The silver-plated bus terminals and water-cooling inlet / outlet ports of each coil segment are located on the outer side above the coil. The entire segmented water-cooled multiplexed coil can achieve two working modes: leakage magnetic induction power generation and high-frequency eddy current assisted heating, in a time-division manner. The coil series-parallel electronic control switching module is electrically connected to the silver-plated bus terminals of each coil segment, and has two wiring modes: full parallel and series-parallel combination. The full parallel connection is switched when the air gap is 50mm and 70mm; the series-parallel combination connection is switched when the air gap is expanded to 90mm; and the full parallel connection is forcibly switched when the high-frequency auxiliary heating mode is used. The dual-circuit interlocking switching module has a built-in electrical interlocking structure, which connects only one of the rectifier energy storage module and the high-frequency inverter heating power supply at any given time. The temperature control and energy consumption control unit collects hub temperature and working air gap signal between disk and coil, and automatically controls the switching of coil wiring mode and working circuit; The rectifier energy storage module is electrically connected to the high-frequency inverter heating power supply and the permanent magnet disk main servo motor driver. The rectifier energy storage module has built-in power scheduling logic: the stored power is given priority to the high-frequency inverter heating power supply, and the surplus power after meeting the high-frequency heating power demand is output to compensate for the power consumption of the permanent magnet disk main servo motor.

2. The integrated heat preservation device for hub leakage magnetic power generation and high-frequency auxiliary heating according to claim 1, characterized in that: The segmented water-cooled multiplexed coil is sequentially wrapped with polyimide high-temperature insulating tape and mica composite insulating sleeve, with high-temperature resistant thermally conductive epoxy resin filling the interlayer; a 0.5mm insulation gap is reserved between turns and filled with high-temperature resistant thermally conductive epoxy resin.

3. The integrated heat preservation device for hub leakage magnetic power generation and high-frequency auxiliary heating according to claim 1, characterized in that: The segmented water-cooled multiplexed coil is internally circulated with 1.2MPa industrial refrigeration soft water for cooling, and the water-cooling pipelines of each coil segment are connected in parallel to the water distributor; the entire coil withstands 5kV power frequency for 1 minute without breakdown, and the water-cooling circuit withstands 1.2MPa pressure for 30 minutes without leakage.

4. The integrated heat preservation device for hub leakage magnetic power generation and high-frequency auxiliary heating according to claim 1, characterized in that: The ring-shaped protective frame is integrally molded from glass fiber reinforced high-temperature resistant PA66 non-magnetic plastic. The inner side of the frame is provided with an arc-shaped slot for limiting segmented water-cooled reusable coils, and the inner wall of the slot is pasted with a multi-layer composite heat insulation lining.

5. The integrated heat preservation device for hub leakage magnetic power generation and high-frequency auxiliary heating according to claim 1, characterized in that: The rectifier energy storage module integrates a supercapacitor and a lithium battery pack to smooth out fluctuations in power generation.

6. A method for coordinated control of leakage magnetic field power generation, high-frequency auxiliary heating, and residual current compensation main disk rotary motor based on the device according to any one of claims 1 to 5, characterized in that, Includes the following steps: S0, Power-on self-test and parameter initialization The system completes hardware self-test upon power-up; the hub specification encoder acquires the real-time air gap between the permanent magnet disk and the segmented water-cooled multiplexed coil; the initial wiring mode of the coil is set according to the air gap; and the power threshold of the rectifier energy storage module is initialized. S1. During the heating start-up phase, the hub temperature is <380℃; the dual-circuit interlock module connects the power generation circuit and cuts off the high-frequency heating circuit; the main servo motor is started to drive the permanent magnet disk to rotate. Multiplexed coils capture leakage flux for power generation and energy storage; no high-frequency heating load, stored energy directly compensates for the power consumption of the main servo motor; continuous monitoring of hub temperature; S2. When the hub temperature reaches 380℃, the coil is forcibly switched to full parallel mode; the power generation circuit is disconnected, and after a delay, the high-frequency inverter heating power supply is connected. S3, 380℃ ≤ hub temperature < 420℃ During the middle and late stages of heating, the reused coil outputs a high-frequency magnetic field to assist in heating the outer wall of the hub; the energy storage module releases electrical energy to prioritize supplying the high-frequency inverter heating power supply, and then compensates for the power consumption of the main servo motor when there is surplus electrical energy. S4. During the constant temperature insulation stage, the wheel hub is maintained at 420℃~450℃, and a 20s cycle control is adopted. In the first 10s of the cycle, the high-frequency heat replenishment mode is run, and the energy storage power is given priority to supply the high-frequency load. In the last 10s of the cycle, the power generation mode is switched, and the energy storage power compensates the main servo motor. The duty cycle of the two working conditions is dynamically adjusted according to the wheel hub temperature. S5. Shutdown procedure: First, disconnect the high-frequency inverter power supply, delay for 20 seconds to maintain the power generation mode to recover residual magnetic field energy, and then shut down the permanent magnet disk drive motor; the water cooling system continues to cool the coils. S6. The entire process executes abnormal protection logic, and performs corresponding safety protection actions when the coil over-temperature, energy storage is depleted, interlock fault occurs, or the workpiece over-temperature occurs.

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