Interleaved induction coil device for bevel conductor welding

Abstract

The application discloses a staggered induction coil device for bevel conductor welding, which comprises a base connecting assembly, a conductive part, an arc-shaped transition section and a heating part. The contact plate is vertically welded with the conductive plate in the base connecting assembly, and an insulating plate is arranged between the two conductive plates to prevent short circuit. The conductive part is a long strip-shaped rectangular conductor, which connects the base and the arc-shaped transition section. The arc-shaped transition section is outwardly arc-shaped, so that the heating part is staggered in front and back. The heating part comprises a first vertical section and a second vertical section which are parallel and staggered, forming a bevel conductor clamping channel. A high-temperature magnetic stability module is arranged on the vertical section, and a baffle is arranged on the outer side. The device is connected through each part, realizes low-consumption transmission of current and uniform focusing of a magnetic field, and further improves welding quality and efficiency.

Description

Technical Field

[0001] This utility model belongs to the technical field of induction welding equipment, and relates to an interleaved induction coil device for welding inclined conductors. Background Technology

[0002] In the welding of inclined conductors such as those used in hydropower station line bar joints, the welded area of ​​the inclined conductor to be welded has a triangular, pointed structure due to its structural design, with significant differences in wall thickness. Traditional induction coils use a single-sided heating structure, where heat is transferred only to the conductor thickness direction through thermal conduction. Uneven wall thickness directly leads to significant differences in the rate of heat accumulation in different areas of the conductor, ultimately forming a large temperature gradient. Local overheating can easily cause conductor melting, while insufficient heating leads to incomplete weld fusion, seriously affecting welding reliability. In the manufacturing of traditional induction coils, all corners rely on welding connections. As a heating device that carries both electricity and water, the weld seam at every point is susceptible to leakage. When operating underwater or in humid environments in river power stations, the weld seam is extremely prone to leakage due to thermal expansion and contraction and water flow impact. Meanwhile, the inclined conductor is made of non-magnetic copper. Copper's high conductivity makes it difficult for electromagnetic fields to penetrate its interior; most of the energy is confined to the surface. Unabsorbed energy is reflected back as waves. When copper reflects electromagnetic fields, some energy is converted into eddy currents (formed by induced currents). These eddy currents are only distributed on the surface, resulting in insufficient heating depth, uneven electromagnetic field distribution, and localized overheating or underheating. This leads to low heating efficiency and high energy consumption. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: an interlaced induction coil device for welding inclined conductors, including a base connection assembly, wherein the base connection assembly is connected to one end of a conductive part for receiving and transmitting current; the other end of the conductive part is connected to an arc-shaped transition section, the arc-shaped transition section is arc-shaped and extends to form a symmetrical structure with spacing, the arc-shaped transition section extends and connects to a heating part for clamping and heating the inclined conductor to be welded.

[0004] The base connection assembly includes a contact plate, a conductive plate, and an insulating plate. The conductive plates are symmetrically and perpendicularly connected to the contact plates. One end of the conductive part forms two poles that are connected to the conductive plates. An insulating plate is provided between the two conductive plates for isolation.

[0005] The conductive part is a long rectangular conductor, one end of which is connected to the base connection assembly, and the other end is connected to the arc-shaped transition section.

[0006] The arc-shaped transition section is an outwardly expanding arc, so that the heating parts connected to the arc-shaped transition section are staggered front and back.

[0007] The heating section includes a first vertical section and a second vertical section, which are parallel and staggered to form a channel for clamping the inclined conductor to be welded.

[0008] The first and second vertical sections of the heating section are connected at one end to the arc-shaped transition section, and the other end is bent downward to form an arc shape that overlaps with the arc-shaped transition section.

[0009] Both the first and second vertical sections are equipped with high-temperature magnetic stability modules to buffer thermal expansion and maintain high-temperature magnetic flux, so that the inclined conductor to be welded located between the first and second vertical sections is heated from both sides, making the heating more uniform.

[0010] The high-temperature magnetic stability module is composed of a magnetic conductor and a mica sheet; baffles are spaced apart on the outer side of the high-temperature magnetic stability module.

[0011] The magnetic conductor and mica sheet are arranged alternately between the baffles, and the length of the mica sheet is adapted to the length of the magnetic conductor.

[0012] The outer sides of the conductive part, the arc-shaped transition section, and the heating part are covered with a composite insulating layer.

[0013] The main beneficial effects of this utility model are as follows: The vertical welding of the conductive plate and the contact plate in the base connection assembly, and the fixed connection of the insulating plate between the two poles, enable a stable and safe current input link, ensuring efficient current conduction and avoiding the risk of short circuits. At the same time, the direct connection between the conductive part and the arc-shaped transition section, combined with the bending connection between the arc-shaped transition section and the vertical section of the heating part, forms a seamless current transmission path, reducing energy loss. Furthermore, the outward-expanding arc-shaped connection structure of the arc-shaped transition section enables the heating part to be staggered front and rear, allowing the magnetic field to uniformly cover the inclined conductor. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0015] Figure 1 This is a schematic diagram of the structure of this utility model.

[0016] Figure 2 This is a side view of the structure of this utility model.

[0017] Figure 3 This is a top view schematic diagram of the welding operation of this utility model.

[0018] Figure 4 This is a schematic diagram of the inclined conductor structure to be welded according to this utility model.

[0019] In the figure: base connection assembly 1; contact plate 11; conductive plate 12; insulating plate 13; conductive part 2; arc transition section 3; heating part 4; first vertical section 41; second vertical section 42; high temperature magnetic stability module 5; magnetic conductor 51; mica sheet 52; baffle 53; composite insulation layer 6. Detailed Implementation

[0020] like Figures 1-4 A staggered induction coil device for welding inclined conductors includes a base connecting assembly 1. The base connecting assembly 1 is connected to one end of a conductive part 2 for receiving and transmitting current. The other end of the conductive part 2 is connected to an arc-shaped transition section 3. The arc-shaped transition section 3 is arc-shaped and extends to form a symmetrical structure with spacing. The arc-shaped transition section 3 extends and connects to a heating part 4 for clamping and heating the inclined conductor to be welded. The base connecting assembly 1, conductive part 2, arc-shaped transition section 3, and heating part 4 are integrally connected, creating a clamping channel for the inclined conductor, allowing the device to adapt to different welding environments. Simultaneously, the conductive part 2 ensures stable current transmission from the base connecting assembly 1 to the heating part 4, thus guaranteeing the overall functionality and practicality of the device.

[0021] Furthermore, the base connection assembly 1 includes a contact plate 11, a conductive plate 12, and an insulating plate 13. The conductive plates 12 are symmetrically and perpendicularly connected to the contact plates 11. One end of the conductive part 2 forms two poles connected to the conductive plates 12, and an insulating plate 13 is provided between the two conductive plates 12 for isolation. The symmetrical and perpendicular connection of the conductive plates 12 to the contact plates 11 forms a stable current transmission path, and the connection method between the conductive part 2 and the conductive plates 12 ensures high efficiency in current transmission. The insulating plate 13 acts as an isolation device between the two conductive plates 12, avoiding short circuits between the poles and improving the safety of the device, ensuring stable and reliable current transmission throughout the entire process.

[0022] Furthermore, the conductive part 2 is a long rectangular conductor, with one end connected to the base connection assembly 1 and the other end connected to the arc-shaped transition section 3. The conductive part 2 receives the current from the base connection assembly 1 and transmits it stably to the arc-shaped transition section 3, thereby reducing energy loss during current transmission.

[0023] Furthermore, the arc-shaped transition section 3 is an outwardly expanding arc shape, so that the heating parts 4 connected to the arc-shaped transition section 3 are staggered front and back. By using the arc-shaped transition section 3 to make the heating parts 4 staggered front and back, an alternating distribution of the magnetic field is formed, so that the magnetic field can act more evenly and more concentratedly on the welding area of ​​the inclined conductor.

[0024] Furthermore, the heating section 4 includes a first vertical section 41 and a second vertical section 42, which are parallel and staggered to form a channel for clamping the inclined conductor to be welded. The heating section 4, composed of the parallel and staggered first vertical section 41 and the second vertical section 42, forms a channel for clamping the inclined conductor to be welded.

[0025] Furthermore, one end of the first vertical segment 41 and the second vertical segment 42 of the heating section 4 are connected to the arc-shaped transition segment 3, and the other end is bent downward to form an arc shape that overlaps with the arc-shaped transition segment 3. The overlapping arc-shaped structure increases the magnetic field strength, allowing more energy to be focused on the welding part of the inclined conductor. This enables the inclined conductor to be heated to a suitable welding temperature in a shorter time, while reducing energy loss and improving energy utilization.

[0026] Furthermore, high-temperature magnetic stability modules 5 are installed on both the first vertical segment 41 and the second vertical segment 42 to buffer thermal expansion and maintain high-temperature magnetic flux. This ensures that the inclined conductor to be welded, located between the two first vertical segments 41 and the two second vertical segments 42, is heated from both sides, resulting in more uniform heating. During the welding process, the material is prone to thermal expansion due to rapid temperature changes. This module effectively buffers the stress caused by thermal expansion, preventing damage to the coil due to thermal expansion and contraction, extending the service life of the device. Simultaneously, it maintains magnetic flux stability under high-temperature conditions, ensuring that the inclined conductor to be welded is heated uniformly from both sides, avoiding welding defects caused by localized overheating or undercooling.

[0027] Furthermore, the high-temperature magnetic stability module 5 is composed of a magnetic conductor 51 and a mica sheet 52. Baffles 53 are spaced apart on the outer side of the high-temperature magnetic stability module 5. The welding height of the baffles 53 is H = h + 2Δh, where Δh = 5-10 mm, h is the height of the inclined conductor joint, and the spacing of the baffles 53 is D = 60-80 mm, used to form a directional magnetic field channel to suppress copper reflection loss. Because the high-temperature magnetic stability module is composed of a magnetic conductor 51 and a mica sheet 52, the magnetic conductor 51 can enhance the magnetic field strength and improve the efficiency of induction heating, while the mica sheet 52 has good insulation and high-temperature resistance properties, effectively preventing short circuits between the magnetic conductors 51, and ensuring the normal operation of the module in high-temperature environments.

[0028] Furthermore, the magnetic conductor 51 and mica sheet 52 are alternately arranged between the baffles 53, and the length of the mica sheet 52 is adapted to the length of the magnetic conductor 51. By alternating the magnetic conductor 51 and mica sheet 52 between the baffles 53 and adapting their lengths, the performance of the high-temperature magnetic stability module 5 is optimized, the disordered conduction of current between the magnetic conductors 51 is avoided, the orderly distribution and stable transmission of the magnetic field are ensured, and the heating effect of the heating part 4 on the inclined conductor is made more uniform and stable, effectively improving the welding quality and reducing welding defects caused by uneven magnetic field.

[0029] Furthermore, the outer sides of the conductive part 2, the arc-shaped transition section 3, and the heating part 4 are covered with a composite insulating layer 6. The composite insulating layer 6 covering the outer sides of the conductive part 2, the arc-shaped transition section 3, and the heating part 4 provides multiple protections, improving the safety of the device during use, and preventing current leakage inside the device, thus avoiding safety accidents caused by leakage.

[0030] Example 1, such as Figure 2 and Figure 4 As shown, during welding, the slope angle θ between the two inclined conductors to be welded is 45°; Parameter settings: θ=45°; L=20mm; Δh=8mm, h=50, H=50+2x8=66; baffle 53 spacing D=70mm; magnetic conductor 51 is made of 0.2mm silicon steel sheet with a magnetic permeability of 4820H / m; mica sheet 52 is 1mm thick.

[0031] The magnetic conductor 51 is embedded between the baffles 53, and mica sheets 52 are embedded between the magnetic conductors 51 at a spacing of 10mm ± 0.5mm; the composite insulation layer 6 covers the coil body; the insulation plate 13 is installed in the middle of the rigid structure formed by welding the contact plate 11 and the conductive plate 12 distributed on both sides to isolate the two poles of the induction coil.

[0032] Heating results: Infrared thermometry showed a temperature gradient of ≤8℃, the melt depth test pass rate was 100%, and the energy consumption was 3.1KW.h.

[0033] Example 2, as Figure 2 and Figure 4 As shown, during welding, the slope angle θ between the two inclined conductors to be welded is 60°; Parameter settings: θ=60°; L=35mm; Δh=8mm, h=50, H=50+2x8=66; baffle 53 spacing D=70mm; magnetic conductor 51 can be ferrite with a permeability of 6500H / m; mica sheet 52 thickness 1mm.

[0034] Heating results: Infrared thermometry showed a temperature gradient of ≤8℃, the melt depth test pass rate was 100%, and the energy consumption was 3.0KW.h.

[0035] Implementation case studies validated that: the temperature gradient was reduced from ±23℃ to ≤±8℃, improving efficiency by 65.2%. The cooling system leakage rate was reduced from 7.3% to 0%, improving efficiency by 100%. The energy consumption per unit joint was reduced from 4.8 kW·h to 3.1 kW·h, an improvement of 35.4%.

[0036] The above embodiments are merely preferred technical solutions of this utility model and should not be considered as limitations on this utility model. The embodiments and features described in this application can be arbitrarily combined without conflict. The protection scope of this utility model should be defined as the technical solution described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the protection scope of this utility model.

Claims

1. A staggered induction coil device for welding inclined conductors, characterized in that: The system includes a base connection assembly (1), which is connected to one end of a conductive part (2) for receiving and transmitting current; the other end of the conductive part (2) is connected to an arc-shaped transition section (3), which is arc-shaped and extends to form a symmetrical structure with spacing. The arc-shaped transition section (3) extends and is connected to a heating part (4) for clamping and heating the inclined conductor to be welded.

2. The interleaved induction coil apparatus for mitered conductor welding of claim 1, wherein: The base connection assembly (1) includes a contact plate (11), a conductive plate (12) and an insulating plate (13). The conductive plate (12) is symmetrically and perpendicularly connected to the contact plate (11). One end of the conductive part (2) forms two poles and is connected to the conductive plate (12). An insulating plate (13) is provided between the two conductive plates (12) for isolation.

3. The interleaved induction coil apparatus for mitered conductor welding of claim 1, wherein: The conductive part (2) is a long rectangular conductor, one end of which is connected to the base connection assembly (1), and the other end is connected to the arc transition section (3).

4. The interleaved induction coil apparatus for mitered conductor welding of claim 1, wherein: The arc-shaped transition section (3) is an outwardly expanding arc shape, so that the heating part (4) connected to the arc-shaped transition section (3) is staggered front and back.

5. The interleaved induction coil apparatus for mitered conductor welding of claim 1, wherein: The heating section (4) includes a first vertical section (41) and a second vertical section (42), which are parallel and staggered to form a channel for clamping the inclined conductor to be welded.

6. The interleaved induction coil apparatus for mitered conductor welding of claim 5, wherein: The first vertical section (41) and the second vertical section (42) of the heating part (4) are connected at one end to the arc transition section (3), and the other end is bent downward to form an arc shape that is stacked with the arc transition section (3).

7. The interleaved induction coil apparatus for mitered conductor welding of claim 5, wherein: Both the first vertical section (41) and the second vertical section (42) are equipped with a high-temperature magnetic stability module (5) to buffer thermal expansion and maintain high-temperature magnetic flux, so that the inclined conductor to be welded located between the first vertical section (41) and the second vertical section (42) is heated from both sides, making it more uniformly heated.

8. The interleaved induction coil apparatus for mitered conductor welding of claim 7, wherein: The high-temperature magnetic stability module (5) is composed of a magnetic conductor (51) and a mica sheet (52); baffles (53) are arranged at intervals on the outer side of the high-temperature magnetic stability module (5).

9. The interleaved induction coil apparatus for mitered conductor welding of claim 8, wherein: The magnetic conductor (51) and mica sheet (52) are arranged alternately between the baffle (53), and the length of the mica sheet (52) is adapted to the length of the magnetic conductor (51).

10. The interleaved induction coil apparatus for mitered conductor welding of claim 1, wherein: The outer sides of the conductive part (2), the arc-shaped transition section (3) and the heating part (4) are covered with a composite insulating layer (6).

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