Coreless Induction Furnace With Automatic Shunt and Head Adjustment
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Solution Overview
Problem
Conventional coreless induction furnaces experience deformation and destruction of components like shunts and heads due to extreme power and heat, leading to time-consuming and labor-intensive disassembly and reassembly, which results in loss of productivity and safety risks for operators.
Innovation Solution
An adjustable shunt and head system with drive assemblies and load cells that automatically adjust the position of shunts and heads relative to cooling and power coils, maintaining desired pressure and preventing deformation through independent and separate adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional coreless induction furnaces operate with extreme power and heat, then melting and alloy mixing efficiency is improved, but deformation and destruction of shunts and heads occurs
Solution Approach 1:
The patent implements adjustable shunt and head systems that can dynamically reposition themselves relative to the cooling and power coils during operation. This dynamic adjustment capability allows the system to maintain optimal pressure conditions and prevent deformation while operating at extreme power levels, resolving the contradiction between productivity and component integrity
Solution Approach 2:
The invention changes the physical parameters of the shunt and head positioning by introducing adjustable mechanisms that can modify their spatial coordinates and pressure conditions. By controlling parameters such as position, pressure, and alignment, the system prevents deformation while maintaining high-power operation, thus resolving the technical contradiction
2Temperature
If cooling coils are added to reduce heat, then thermal management is improved, but unwanted pressure and stress on shunts and heads increases leading to warpage
Solution Approach 1:
The patent applies local quality by providing independent and separate adjustment mechanisms for shunts and heads, allowing each component to be optimized for its specific pressure and thermal conditions. This localized control prevents uniform stress distribution that causes warpage, while maintaining effective cooling, thus resolving the contradiction between temperature control and pressure management
3Stability of the object's composition
If shunts and heads are constantly maintained at sustained pressure, then component stability is improved, but warpage and deformation occur over time
Solution Approach 1:
The invention transforms the static pressure maintenance system into a dynamic one where shunts and heads can adjust their positions and pressure conditions in real-time. This dynamic capability allows the system to maintain stability without subjecting components to continuous sustained pressure that causes warpage, resolving the contradiction between stability and shape integrity
4Ease of repair
If manual disassembly and reassembly is performed to replace deformed components, then component replacement is achieved, but time loss and labor intensity increase
Solution Approach 1:
The patent implements self-service through automated adjustment mechanisms that can reposition and recalibrate shunts and heads without requiring manual disassembly or reassembly. The adjustable systems can compensate for deformation in-situ, eliminating the need for time-consuming manual intervention and component replacement, thus resolving the contradiction between ease of repair and time loss
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 system effectively reduces component deformation, enhances operational safety, and increases productivity by minimizing manual intervention and maintaining optimal pressure conditions during melting processes.
Implementation Method 1
induction furnaces, either coreless or channel, operate by transferring high and/or extreme amounts heat energy via a high-voltage primary coil that induces a high current with a low voltage
Implementation Method 2
these coreless induction furnaces generate high and/or extreme amounts of heat energy through these power coils at high current values where frequencies may vary between about 50 cycles per second up to about 10,000 cycles per second
Implementation Method 3
conventional coreless induction furnaces may include coils that are fluid-cooled (e.g., water-cooled or other fluids of the like) via a recirculating tower or machine
Data Source
AI summary
A coreless induction furnace that is automatically adjustable during assembly operations or melting operations. The furnace may include an outer shell, a set of adjustable shunt systems that operably engages with the outer shell, at least one cooling coil that operably engages with the set of adjustable shunt systems, and a power coil that operably engages with the at least one cooling coil and the set of adjustable shunt systems. The furnace is configured to automatically adjust at least one shunt of the set of adjustable shunt systems relative to at least one of the at least one cooling coil and the power coil. The furnace may also include an adjustable head system that operably engages with the outer shell. The adjustable head system is configured to automatically adjust a head of the adjustable head system relative to the at least one cooling coil and the power coil.