Double-Sided Flat Inductor Assembly with Rapid Extraction
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Solution Overview
Problem
Existing manufacturing processes face challenges in simultaneously heating two separate workpieces with different geometries using electric induction, particularly in achieving uniform heating profiles for subsequent welding, and efficiently removing the inductor assembly for joining purposes.
Innovation Solution
A double-sided flat inductor assembly with spirally-coiled induction coils and an extraction apparatus that positions and rapidly removes the inductor between workpieces, ensuring uniform heating and efficient electromagnetic disconnection for post-heating processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single inductor assembly is used to heat two separate workpieces simultaneously, then heating efficiency is improved, but the inductor assembly interferes with the subsequent joining process
Solution Approach 1:
The inductor assembly is designed with movable components that allow it to transition between a first position for simultaneous heating of both workpieces and a second position that clears the joining area. This dynamic repositioning enables the system to maintain heating efficiency while eliminating interference with the subsequent joining process.
2Manufacturing precision
If the inductor assembly remains in position after heating, then heating uniformity is maintained, but heat dissipation increases and joining is delayed
Solution Approach 1:
The system performs the heating action completely while the inductor is in the first position, ensuring uniform heating is achieved before the inductor is moved. The rapid transition to the second position then prevents heat dissipation and allows immediate joining, thus maintaining heating uniformity while minimizing joining delay.
3Manufacturing precision
If separate inductors are used for each workpiece, then heating control is improved, but device complexity increases
Solution Approach 1:
The system combines multiple inductor assemblies into a single integrated unit that can simultaneously heat both workpieces. This merged structure maintains the heating control capabilities of individual inductors while reducing overall device complexity and enabling coordinated operation for simultaneous 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
Enables simultaneous induction heating of complementary workpiece sides with uniform heating profiles and rapid inductor extraction, facilitating efficient joining by minimizing heat dissipation and interference during the welding process.
Implementation Method 1
double-sided flat inductor assembly for simultaneous induction heating of two separate workpieces
Implementation Method 2
spirally-coiled induction coils
Implementation Method 3
induction heating of complementary workpiece sides
Data Source
AI summary
A double-sided flat inductor assembly is provided for simultaneous induction heating of two separate workpieces positioned on opposing sides of the double-sided flat inductor assembly. An extraction assembly is provided for rapid removal of the inductor assembly after completion of the simultaneous induction heating of the two separate workpieces which eliminates the necessity of using flexible electrical cables and allows improved performance of an induction system including increased reliability.