Inductor with short circuit prevention isolation mechanism

Abstract

The utility model relates to the field of inductors, and discloses an inductor with a short circuit prevention isolation mechanism, which comprises an annular inductor and a short circuit prevention structure arranged on the annular inductor and used for preventing short circuit of the annular inductor, the short circuit prevention structure comprises an insulating layer detachably arranged on the inner ring wall of the annular inductor, a supporting part for limiting the insulating layer from being separated from the inner ring wall of the annular inductor, and a heat insulation unit arranged outside the supporting part and used for preventing the supporting part and the insulating layer from being overheated; according to the inductor with the short circuit prevention isolation mechanism, short circuit ablation caused by direct contact between the annular inductor and a part in the moving process is avoided, the safety is improved, meanwhile, the quality of the part is guaranteed, and the service life of the annular inductor is prolonged.

Description

Technical Field

[0001] The utility model relates to the field of sensors, and in particular to a sensor with an anti-short circuit isolation mechanism. Background Art

[0002] Parts such as piston rods or screws in industries such as plastic machinery usually require surface induction hardening to improve surface wear resistance and hardness. That is, a ring sensor is placed on the part, and the ring sensor is moved along the length of the part while the part is rotated to perform rotary induction heating quenching. For details, please refer to Figure 1 However, some parts are long in length. If vertical induction quenching is used, it is necessary to dig a deep pit in the factory or build an extra-high factory building, which will incur huge infrastructure costs. Therefore, horizontal induction quenching is generally used for long parts.

[0003] However, during the horizontal induction hardening process, the two ends of the part are fixed. Under the action of its own gravity, the closer the part is to the center, the easier it is to bend and deform. At the same time, the internal stress of the part before induction hardening due to the raw materials, previous tempering heat treatment and machining, as well as the thermal stress caused by the temperature difference between the surface and the core caused by rapid heating, the superposition and release of these stresses will also cause the part to bend, resulting in the part rotating and jumping during the rotation process, that is, one side is far away from the annular sensor, and the other opposite side is very close to the annular sensor. Due to the characteristic that the closer the part is to the annular sensor, the higher the heating efficiency, the greater the curvature, the more uneven the heating on both sides of the sensor, forming a vicious cycle of continuous accumulation of curvature.

[0004] In more serious cases, at the point where the part is deformed to the maximum, the bending deformation of the part exceeds the original spacing between the part and the annular sensor, and the part and the annular sensor directly contact and cause a short circuit, causing the contact point to instantly generate a high temperature similar to welding, and the surface here will be burned into a pit. However, the part is almost a finished product during induction quenching, and the outer diameter machining allowance is not enough to remove the ablation pit by mechanical processing, so the part can only be scrapped. At the same time, the short circuit will also cause local overheating of the sensor, affecting its service life, severe deformation or melting, or even direct scrapping.

[0005] Chinese patent application number 201820896443.7 discloses a sensor with an anti-spark coating, including an effective section of the sensor, a surface nylon coating, and a cold water inner cavity. The surface of the effective section of the sensor is sandblasted and dipped with a layer of primer, and the outer layer of the effective section of the sensor is sprayed with a layer of surface nylon coating. The effective section of the sensor is hollow to form an internal cold water inner cavity. Cooling water is passed through the cold water inner cavity to keep the temperature of the surface nylon coating below its melting point.

[0006] However, the nylon coating in this patent has no hardness. In the actual process of processing parts, the nylon coating may be squeezed and partially damaged after being scratched by steel parts. In addition, the nylon coating is not only heated by the sensor, but also directly receives radiant heat from the parts that are rapidly heated by the sensor at nearly 900°C, which can easily make the low-melting-point nylon coating fail. Damage or failure of the nylon coating will cause short-circuit and burning between the parts and the annular sensor, and the safety performance is relatively low. Utility Model Content

[0007] The utility model aims at the disadvantages of the prior art that the nylon coating is easily damaged and invalid, resulting in short-circuit ablation of parts in contact with the annular sensor, and provides a sensor with an anti-short-circuit isolation mechanism.

[0008] In order to solve the above technical problems, the utility model is solved by the following technical solutions:

[0009] A sensor with an anti-short circuit isolation mechanism includes an annular sensor and an anti-short circuit structure arranged on the annular sensor to prevent the annular sensor from short circuiting. The anti-short circuit structure includes an insulating layer detachably arranged on the inner ring wall of the annular sensor, a supporting component that limits the insulation layer from separating from the inner ring wall of the annular sensor, and a heat insulation unit arranged outside the supporting component to prevent the supporting component and the insulating layer from overheating.

[0010] With the above solution, the insulating layer covers the inner wall of the entire annular sensor. Since the insulating layer has insulating and wear-resistant properties, it will not be damaged when the parts are bent, squeezed, and rubbed against the insulating layer, and the insulating effect can be reliably achieved. The insulating layer is detachably attached to the inner wall of the annular sensor through the support component. When the insulating layer is damaged, it can be replaced through the support component, and the replacement cost is low and relatively convenient. A heat insulation unit is set on the support component to block most of the radiant heat from the high-temperature parts heated by the induced current, reduce the high temperature impact on the entire support component and the insulating layer, and extend the service life.

[0011] Preferably, the supporting component includes a non-closed circular ring with an opening. When the non-closed circular ring is tensioned, it can cooperate with the annular sensor to clamp the insulating layer; when the non-closed circular ring is relaxed, it can be separated from the insulating layer to release the clamping of the insulating layer. A control structure that can tighten or relax the non-closed circular ring is provided between the two ends of the opening of the non-closed circular ring.

[0012] With the above solution, the annular sensor, the insulating layer and the non-enclosed ring are placed in sequence from the outside to the inside along the radial direction of the annular sensor. The non-enclosed ring is tensioned by the control structure. After the non-enclosed ring is tensioned, its outer ring wall and the inner ring wall of the annular sensor cooperate to clamp the insulating layer; conversely, the control structure drives the non-enclosed ring to be in a non-tensioned state, that is, the non-enclosed ring is separated from the insulating layer after relaxation, and the insulating layer can be replaced. In addition, before the insulating layer contacts the parts, the non-enclosed ring serves as the first protective structure to limit the contact between the parts and the annular sensor, further improving the anti-short circuit performance of the sensor.

[0013] Preferably, the control structure includes slots respectively recessed at two ends of the opening of the non-closed circular ring and connecting wedges respectively located in the two slots at two ends.

[0014] By adopting the above scheme, the connecting wedge is rigid. When the two ends of the connecting wedge are respectively inserted into the two slots, the two ends of the non-closed ring can be prevented from approaching each other, that is, the non-closed ring is ensured to be in a taut state, and the insulating layer can be clamped in cooperation with the annular sensor; conversely, if either end of the connecting wedge is detached from the slot, the two ends of the non-closed ring can approach each other or be misaligned, and the non-closed ring can be deformed, making it easy to remove.

[0015] Preferably, both ends of the connecting wedge are detachably plugged into the slots.

[0016] By adopting the above solution, the non-closed circular ring can be tensioned and the connecting wedge can be easily replaced when the connecting wedge is damaged.

[0017] Preferably, one end of the connecting wedge is fixedly connected to any one of the slots and the other end is detachably plugged into the remaining slots.

[0018] By adopting the above solution, the non-closed circular ring can be tensioned while avoiding the loss of the connecting wedge.

[0019] Preferably, the cross section of the connecting wedge is rectangular or shuttle-shaped.

[0020] With the above solution, the connecting wedge block can be rectangular or shuttle-shaped to limit the deformation of the non-closed circular ring and make it tight, and the shuttle-shaped setting can make the tension of the non-closed circular ring higher.

[0021] Preferably, the thermal insulation unit comprises a first thermal insulation layer coated on the surface of the non-closed annular ring.

[0022] With the above solution, the first heat insulation layer blocks the radiated heat from the high-temperature parts heated by the induced current, ensuring that the entire non-enclosed ring is not affected by high temperature; in addition, the heat from the parts radiates outward along the radial direction of the annular inductor, preferentially passing through the heat insulation layer and the non-enclosed ring before reaching the insulating layer, greatly reducing the amount of heat received by the insulating layer. Therefore, the first heat insulation layer also plays a role in preventing the insulating layer from being affected by high temperature. When the first heat insulation layer is installed, its length is slightly larger than the circumference of the non-enclosed ring, so that after the non-enclosed ring is connected and tensioned with the connecting wedge, the connecting surface is not exposed to high temperature, thereby protecting the connecting surface.

[0023] Preferably, an auxiliary thermal insulation structure is provided on the connecting wedge, and the auxiliary thermal insulation structure comprises a second thermal insulation layer coated on the surface of the connecting wedge.

[0024] With the above solution, the surface of the connecting wedge is covered with the second heat insulation layer to protect the connecting wedge from being affected by high temperature. The second heat insulation layer is inserted into the slot together with the connecting wedge to form an integral fixation.

[0025] Preferably, the thickness of the insulating layer is 0.05-0.25 mm, the thickness of the non-closed ring is 0.3-0.6 mm, the thickness of the first thermal insulation layer is 0.06-0.15 mm, and the total thickness of the first thermal insulation layer, the non-closed ring and the insulating layer is less than or equal to 1 mm.

[0026] When adopting the above solution, if the thickness is too thin, it is easy to be damaged; if it is too thick, it is too close to the surface of the part and is easy to contact. The total thickness of the first insulation layer, the non-closed ring and the insulating layer is less than or equal to 1mm to avoid excessive thickness blocking part of the induced magnetic lines and causing reduced heating efficiency.

[0027] Preferably, the non-enclosed circular ring and the connecting wedge are made of high temperature resistant plastic, and the insulating layer is made of insulating wear-resistant material.

[0028] By adopting the above scheme, the non-closed circular ring and the connecting wedge block have high temperature resistance, and the insulating layer has insulating and wear-resistant properties.

[0029] The utility model has remarkable technical effects due to the adoption of the above technical scheme: the insulating layer covers the inner wall of the entire annular sensor, and since the insulating layer has insulating and wear-resistant characteristics, the insulating layer will not be damaged when the parts are bent, squeezed and rubbed against the insulating layer, and the insulating effect can be reliably achieved; the heat-insulating layer and the non-closed circular ring clamp the insulating layer on the inner ring wall of the annular sensor and serve as the first protective structure to limit the contact between the parts and the annular sensor, further improving the anti-short-circuit performance of the sensor, improving safety while ensuring the quality of the parts, and extending the service life of the annular sensor; the heat-insulating layer can also isolate the heat radiation from the parts, and extend the service life of the non-closed circular ring and the insulating layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is the arrangement method of the parts and the ring sensor in the prior art;

[0031] Figure 2 is a front view of a sensor with an anti-short circuit isolation mechanism in an embodiment;

[0032] Figure 3 yes Figure 2 Sectional view at AA in the figure;

[0033] Figure 4 yes Figure 3 The enlarged view of point B in the figure;

[0034] Figure 5 is a top view of a sensor with an anti-short circuit isolation mechanism in an embodiment;

[0035] Figure 6 yes Figure 5 Sectional view at CC in FIG.

[0036] Figure 7 yes Figure 6 Enlarged view of point D in .

[0037] The names of the parts indicated by the numerical labels in the above figures are as follows: 1. annular sensor; 2. insulating layer; 3. non-closed circular ring; 4. slot; 5. connecting wedge; 6. first thermal insulation layer; 7. second thermal insulation layer; 8. parts. DETAILED DESCRIPTION

[0038] The utility model is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0039] Example

[0040] A sensor with an anti-short circuit isolation mechanism, referring to Figures 2 to 7 , including an annular sensor 1, and a water spray hole for cooling is arranged on the side wall of the annular sensor 1. An insulating layer 2 is detachably arranged on the inner ring wall of the annular sensor 1, and the insulating layer 2 does not block the water spray hole. The insulating layer 2 is installed on the inner ring wall of the annular sensor 1 through a supporting structure. The insulating layer 2 is made of an insulating wear-resistant material, so that the insulating layer 2 has insulating wear-resistant properties.

[0041] The insulating layer 2 covers the inner wall of the entire annular sensor 1. Since the insulating layer 2 has insulating and wear-resistant properties, when the part 8 is bent, squeezed, and rubbed against the insulating layer 2, it will not be damaged, and the insulating effect can be reliably achieved. The insulating layer 2 is detachably attached to the inner wall of the annular sensor 1 through a supporting component. When the insulating layer 2 is damaged, it can be replaced through the supporting component, and the replacement cost is low and relatively convenient.

[0042] The supporting structure includes a non-closed circular ring 3 with an opening. The non-closed circular ring 3 can be formed into a circular ring by injection molding and then broken at a certain point; it can also be made by breaking a ready-made high-temperature resistant plastic circular ring. A control structure is arranged between the two ends of the opening of the non-closed circular ring 3. The annular sensor 1, the insulating layer 2 and the non-closed circular ring 3 are placed in sequence from the outside to the inside along the radial direction of the annular sensor 1. The non-closed circular ring 3 is tensioned by the control structure. After the non-closed circular ring 3 is tensioned, its outer ring wall and the inner ring wall of the annular sensor 1 cooperate to clamp the insulating layer 2; conversely, the control structure drives the non-closed circular ring 3 to be in a non-tensioned state, that is, the non-closed circular ring 3 is separated from the insulating layer 2 after relaxation, and the insulating layer 2 is replaced. In addition, the non-closed circular ring 3 can also serve as a first protective structure to limit the contact between the part 8 and the annular sensor 1, further improving the anti-short circuit performance of the annular sensor 1.

[0043] The control structure includes slots 4 respectively recessed at both ends of the opening of the non-closed circular ring 3 and connecting wedges 5 respectively located in the two slots 4. The connecting wedge 5 has rigidity, and when the two ends of the connecting wedge 5 are respectively inserted into the two slots 4, the two ends of the non-closed circular ring 3 can be prevented from approaching each other, that is, the non-closed circular ring 3 is ensured to be in a taut state, and the insulating layer 2 can be clamped with the annular sensor 1; on the contrary, any end of the connecting wedge 5 is separated from the slot 4, the two ends of the non-closed circular ring 3 can approach each other or be misaligned, and the non-closed circular ring 3 can be deformed, which is easy to remove.

[0044] The two ends of the connecting wedge 5 are detachably connected to the slot 4, so that the non-enclosed ring 3 can be tightened and the connecting wedge 5 can be easily replaced when it is damaged. The cross section of the connecting wedge 5 is rectangular or shuttle-shaped. The connecting wedge 5 can limit the deformation of the non-enclosed ring 3 and tighten it. The shuttle-shaped setting makes the tension of the non-enclosed ring 3 higher. In this embodiment, it is set to be shuttle-shaped. The non-enclosed ring 3 and the connecting wedge 5 are made of high-temperature resistant plastic, so that both have high-temperature resistance.

[0045] The surface of the non-closed circular ring 3 is coated with a first heat-insulating layer 6, which blocks the radiant heat from the high-temperature part 8 heated by the induced current, ensuring that the entire non-closed circular ring 3 is not affected by the high temperature; in addition, the heat from the part 8 radiates outward along the radial direction of the annular inductor 1, and preferentially passes through the heat-insulating layer and the non-closed circular ring 3 before reaching the insulating layer 2, greatly reducing the amount of heat received by the insulating layer 2. Therefore, the first heat-insulating layer 6 also plays a role in reducing the high-temperature radiation received by the insulating layer 2. When the first heat-insulating layer 6 is installed, its length is slightly larger than the circumference of the non-closed circular ring 3, so that the connection surface of the non-closed circular ring 3 and the connecting wedge 5 are not exposed to high temperature after being connected and tensioned, thereby protecting the connection surface.

[0046] An auxiliary thermal insulation structure is provided on the connecting wedge block 5, and the auxiliary thermal insulation structure includes a second thermal insulation layer 7 coated on the surface of the connecting wedge block 5 to protect the connecting wedge block 5 from being affected by high temperature. The second thermal insulation layer 7 is inserted into the slot 4 together with the connecting wedge block 5 to form an integral fixation.

[0047] In this embodiment, the materials of the first heat insulation layer 6 and the second heat insulation layer 7 are mica; and the insulating wear-resistant material is glass ribbon.

[0048] The thickness of the insulating layer 2 is 0.05-0.25mm, the thickness of the non-closed circular ring 3 is 0.3-0.6mm, the thickness of the first thermal insulation layer 6 is 0.06-0.15mm, and the total thickness of the first thermal insulation layer 6, the non-closed circular ring 3 and the insulating layer 2 is less than or equal to 1mm. If the thickness is too thin, it is easy to be damaged, and if it is too thick, it is too close to the surface of the part 8 and is easy to contact. The total thickness of the first thermal insulation layer 6, the non-closed circular ring 3 and the insulating layer 2 is less than or equal to 1mm to avoid excessive thickness blocking part of the induced magnetic lines and causing reduced heating efficiency.

[0049] The specific steps of processing parts using the ring sensor 1 are as follows:

[0050] 1. Place an insulating layer 2 on the inner wall of the annular sensor 1, fit the first thermal insulation layer 6 to the inner surface of the non-closed circular ring 3 and fold it to wrap the non-closed circular ring 3, place the non-closed circular ring 3 covered with the first thermal insulation layer 6 into the annular sensor 1, make the first thermal insulation layer 6 stick to the insulating layer 2 away from the part 8, and then insert the two ends of the connecting wedge 5 wrapped with the second thermal insulation layer 7 into the two slots 4 of the non-closed circular ring 3 respectively, tighten the non-closed circular ring 3, and clamp the insulating layer 2 on the annular sensor 1.

[0051] Second, according to the existing induction hardening operation, first move the installed annular inductor 1 to the outside of the ejector, use a crane to lift the part 8 into the induction hardening machine, and fix the two ends of the part 8 with ejectors. Start rotating the part 8, and automatically move it into the annular inductor 1 through the CNC program setting to perform induction hardening.

[0052] 3. After induction hardening, the annular sensor 1 returns to its original position, the part 8 is removed, and the annular sensor 1 is observed to be intact, and the next part 8 is prepared, and steps 2 and 3 are repeated.

[0053] Step 2 and step 3 are prior art and will not be described in detail here.

Claims

1. A sensor with an anti-short circuit isolation mechanism, comprising a ring-shaped sensor (1) and an anti-short circuit structure arranged on the ring-shaped sensor (1) to prevent the ring-shaped sensor (1) from short circuiting, characterized in that: The short-circuit prevention structure comprises an insulating layer (2) detachably arranged on the inner ring wall of the annular inductor (1), a supporting component for limiting the detachment of the insulating layer (2) from the inner ring wall of the annular inductor (1), and a heat insulation unit arranged outside the supporting component for preventing the supporting component and the insulating layer (2) from overheating.

2. The sensor with an anti-short circuit isolation mechanism according to claim 1, characterized in that: The supporting component comprises a non-enclosed circular ring (3) having an opening. When the non-enclosed circular ring (3) is tightened, it can cooperate with the annular sensor (1) to clamp the insulating layer (2); when the non-enclosed circular ring (3) is relaxed, it can be separated from the insulating layer (2) to release the clamping of the insulating layer (2). A control structure that can tighten or relax the non-enclosed circular ring (3) is arranged between the two ends of the opening of the non-enclosed circular ring (3).

3. The sensor with an anti-short circuit isolation mechanism according to claim 2, characterized in that: The control structure comprises slots (4) respectively recessed at two ends of the opening of the non-closed circular ring (3) and connecting wedges (5) respectively located in the two slots (4) at two ends.

4. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: The two ends of the connecting wedge (5) are detachably plugged into the slot (4).

5. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: One end of the connecting wedge (5) is fixedly connected to any one of the slots (4) and the other end is detachably plugged into the remaining slots (4).

6. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: The cross section of the connecting wedge (5) is rectangular or shuttle-shaped.

7. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: The heat insulation unit comprises a first heat insulation layer (6) coated on the surface of the non-closed circular ring (3).

8. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: An auxiliary heat insulation structure is provided on the connecting wedge block (5), and the auxiliary heat insulation structure comprises a second heat insulation layer (7) coated on the surface of the connecting wedge block (5).

9. The sensor with an anti-short circuit isolation mechanism according to claim 8, characterized in that: The thickness of the insulating layer (2) is 0.05-0.25 mm, the thickness of the non-enclosed circular ring (3) is 0.3-0.6 mm, the thickness of the first thermal insulation layer (6) is 0.06-0.15 mm, and the total thickness of the first thermal insulation layer (6), the non-enclosed circular ring (3) and the insulating layer (2) is less than or equal to 1 mm.

10. The sensor with an anti-short circuit isolation mechanism according to claim 3, characterized in that: The non-enclosed circular ring (3) and the connecting wedge (5) are made of high-temperature resistant plastics, and the insulating layer (2) is made of insulating wear-resistant material.

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