Conduction Heating Device for Hot Stamping
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Solution Overview
Problem
Existing heating technologies for producing high-strength stamped parts, such as continuous fuel and electric furnaces, and induction heating, face inefficiencies in space utilization and heating rates, leading to high energy consumption and production costs, with radiation heating being the least efficient and induction heating being limited by equipment size and heating rate.
Innovation Solution
An automatic controlled electric conduction heating device utilizing Joule effect heating with copper electrodes and internal cooling channels, achieving faster heating rates and higher energy efficiency by minimizing equipment size and optimizing energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If continuous fuel or electric furnaces are used for heating, then the heating process can be performed, but the space consumption is large due to the long path required to raise the temperature
Solution Approach 1:
The patent replaces the mechanical conveyor-based heating system with an electric conduction heating system where the workpiece is heated in place between electrodes. This substitution eliminates the need for long heating paths and conveyor mechanisms, dramatically reducing space consumption while achieving the required heating capability.
Solution Approach 2:
The patent transitions from one-dimensional linear heating (through long furnace paths) to three-dimensional volumetric heating (through internal electric current generation). By inducing current throughout the workpiece volume, heating occurs simultaneously throughout the material rather than progressing along a linear path, reducing the required equipment footprint.
2Temperature
If radiation heating is used, then heating can be performed, but the heating rate is low at approximately 6.5°C/sec
Solution Approach 1:
The patent replaces radiation heating with electric conduction heating. By inducing electric current directly within the workpiece, heat is generated internally through resistive heating rather than being transferred from external sources. This fundamental mechanism change enables heating rates up to 400°C/sec, dramatically exceeding the 6.5°C/sec limitation of radiation heating.
3Speed
If induction heating is used, then heating rate can reach 200°C/sec, but the equipment size and space utilization remain suboptimal
Solution Approach 1:
The patent merges the heating and clamping functions into a single integrated electrode system. The electrodes serve dual purposes: applying mechanical force to hold the workpiece and conducting electric current to generate heat. This consolidation eliminates separate heating coils and clamping mechanisms, reducing equipment size while maintaining high heating rates.
Solution Approach 2:
The electrodes in the patent perform multiple functions simultaneously: they provide mechanical support and positioning for the workpiece, apply clamping force to ensure proper contact, and conduct electric current to generate heat through resistive heating. This multi-functionality reduces the number of separate components needed, minimizing equipment footprint.
4Temperature
If conventional heating methods are used, then heating can be performed, but energy efficiency is low with radiation heating at 26% and induction heating at 40-60%
Solution Approach 1:
The patent replaces external heating methods (radiation or induction) with internal heat generation through electric conduction. By inducing current directly within the workpiece material, heat is generated where needed rather than being transferred from external sources. This eliminates significant energy losses associated with heat transfer, achieving 87% energy efficiency compared to 26% for radiation and 40-60% for induction heating.
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 conduction heating device achieves heating rates up to 400°C/sec, twice as fast as induction and 61 times faster than radiation, with 87% energy efficiency, significantly reducing production costs and improving space utilization.
Implementation Method 1
heating takes place by conduction (heating by Joule effect)
Implementation Method 2
copper electrodes and internal cooling channels
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
This patent comprises an automatic controlled electric heating device for the production of stamped parts, by tool hardening from hot stamping of the material with specific raw material, granting greater hardness and mechanical resistance to the part, which allows the creation of lighter end products which support greater loads and impacts, consisting basically of the following parts: heating controller system (2), power controller system (3), power transformer (4), data acquisition system (5), mechanical fastening device (6) of the part (P) and performance of electrical contact, and thermal expansion compensation system.