Induction Heating of Bearing Rings With Uniform Radial Temperature
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Solution Overview
Problem
Existing induction heating methods for ring-shaped members, such as outer and inner rings of bearings, struggle to evenly heat components with varying radial thicknesses, leading to uneven temperature distribution and increased manufacturing costs due to the need for customized coils and reduced productivity.
Innovation Solution
The method involves using induction coils positioned either radially inward or outward without the other, with effective lengths exceeding the axial length of the ring, and performing multiple heating steps to achieve uniform heating, including a first and second heating step with different target temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both radially outer side coil portion and radially inner side coil portion are disposed and electrically connected in series, then currents flowing in both coil portions can be made equivalent and heating can be performed under substantially the same conditions, but when targeted at ring-shaped members having different radial thicknesses, the temperature increase rate becomes uneven and it is difficult to evenly heat the entire ring-shaped member
Solution Approach 1:
The patent divides the heating system into two independent heating modes: single-sided heating (using only outer or only inner coil) and dual-sided heating (using both coils independently). This segmentation allows selection of the appropriate heating mode based on the specific workpiece geometry, resolving the contradiction between heating uniformity and efficiency for different radial thickness configurations
Solution Approach 2:
The patent introduces dynamic control of coil current supply, allowing the system to switch between different heating configurations (single-sided/dual-sided, series/parallel connection) based on the workpiece characteristics. This dynamic adaptability enables optimal heating performance across varying radial thicknesses while maintaining productivity
2Manufacturing precision
If the value of current supplied to the coil is reduced to keep down the difference in temperature increase rate, then heating uniformity may be improved, but productivity decreases
Solution Approach 1:
The patent employs periodic or sequential heating cycles where different coil configurations are applied in sequence. For example, initial rapid heating followed by uniformity-correcting heating phases, allowing the system to achieve both high productivity and temperature uniformity through time-dependent control strategies
3Manufacturing precision
If coils are customized to match different diameters and shapes of ring-shaped members, then heating precision can be improved, but manufacturing costs increase due to the need for frequent coil replacements
Solution Approach 1:
The patent designs the induction heating apparatus with universal coils that can function in multiple configurations (inner coil, outer coil, both simultaneously) and support various workpiece types. This multi-functionality eliminates the need for customized coils for each workpiece geometry, reducing manufacturing costs while maintaining heating accuracy through flexible configuration
4Manufacturing precision
If the effective length of the induction coil is set to be larger than the axial length of the ring-shaped member, then the entire ring-shaped member can be heated evenly, but device complexity increases
Solution Approach 1:
The patent applies the principle of excessive action by using coil effective lengths that exceed the minimum required axial coverage. This ensures that the magnetic field fully penetrates the workpiece axial dimensions, guaranteeing uniform heating along the entire axial length without requiring complex multi-coil arrangements or precise positioning mechanisms
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
This approach allows for even and efficient heating of the entire ring-shaped member, reducing manufacturing costs and improving productivity by using versatile coils that can handle varying shapes and sizes without the need for frequent replacements.
Implementation Method 1
induction-heating a ring-shaped member by supplying a current to an induction coil
Implementation Method 2
induction-heating the ring-shaped member using the induction coil
Implementation Method 3
supplying a current to an induction coil
Data Source
AI summary
A ring-shaped member is induction-heated by supplying a current to an induction coil. An induction heating step includes induction-heating the ring-shaped member using an induction coil disposed at a radially inward position of the ring-shaped member in a state in which no substantial coil is disposed at a radially outward position of the ring-shaped member, or induction-heating the ring-shaped member using an induction coil disposed at the radially outward position of the ring-shaped member in a state in which no substantial coil is disposed at the radially inward position of the ring-shaped member. Effective lengths of the induction coils are set to be larger than an axial length of the ring-shaped member.