Arc-Shaped Heating Coil for Uniform Induction
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Solution Overview
Problem
Existing heating coils with annular configurations face challenges in uniformly heating axis-shaped workpieces due to low magnetic field intensity near gaps, particularly when the workpiece cannot be rotated, leading to inefficient electromagnetic induction and temperature distribution.
Innovation Solution
A heating coil design featuring multiple loop portions with arc-shaped connection portions that rotate and maintain constant distance to the workpiece, enhancing magnetic field utilization and dispersion, allowing for uniform heating without workpiece rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a linear lead intermediate portion is used to connect loop portions, then the magnetic field intensity near the gap is compensated, but the distance between the lead intermediate portion and the workpiece increases, reducing electromagnetic induction efficiency
Solution Approach 1:
The lead intermediate portion is configured to extend in an arc shape rather than a straight line, allowing it to maintain a constant distance from the workpiece surface. This curved configuration enables the lead portion to compensate for low magnetic field intensity near gaps while preserving effective electromagnetic induction by keeping the distance to the workpiece constant throughout its length.
2Temperature
If the interval between gaps of loop portions is enlarged to disperse low magnetic field regions, then uniform heating is improved, but the lead intermediate portion becomes longer, increasing the distance issue
Solution Approach 1:
By configuring the lead intermediate portion as an arc-shaped connection that follows the curvature of the loop portions, the effective length is minimized while still achieving the necessary gap dispersion. The arc shape allows the lead portion to span the gap interval efficiently, maintaining constant distance from the workpiece without requiring excessive length.
3Temperature
If multiple loop portions with offset gaps are used, then magnetic field dispersion is improved, but the device complexity increases
Solution Approach 1:
The lead portions are designed to serve dual functions: they electrically connect adjacent loop portions while simultaneously acting as additional heating elements that compensate for low magnetic field intensity in gap regions. This merging of connection and heating functions reduces the need for separate compensatory structures, thereby simplifying the overall device complexity while achieving improved magnetic field distribution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves uniform and efficient heating of the workpiece by effectively utilizing the magnetic field across the entire length of the coil, reducing temperature differences and improving heating efficiency.
Implementation Method 1
When an alternating current (AC) is supplied to the heating coil through which the workpiece is inserted, a magnetic field is formed around the heating coil, an eddy current is generated in the surface layer of the workpiece interlinking with the magnetic flux inside the heating coil, and the workpiece is inductively heated.
Implementation Method 2
an eddy current is generated in the surface layer of the workpiece interlinking with the magnetic flux inside the heating coil
Data Source
AI summary
A heating coil includes a plurality of loop portions disposed coaxially along an axis, a first lead portion and a second lead portion which electrically connect to a power source, and a connection portion which connects the plurality of loop portions, the first lead portion, and the second lead portion in series.