Dual-Inductor Shrink-Fit Chuck Heating for Precise Energy Control
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Solution Overview
Problem
Existing induction heating devices for shrinking tools in and out of tool holders lack efficient energy transfer and control, leading to excessive energy consumption, mechanical complexity, and reduced tool holder lifespan due to inadequate heating and energy distribution.
Innovation Solution
The use of a dual-inductor system with distinct inductors, each with a different number of turns and operational parameters, controlled by a regulating unit to optimize energy transfer and heating precision, allowing for flexible adjustment of energy input to various tool holders, reducing energy consumption, and eliminating the need for complex mechanical adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single inductor or two identical inductors are used for induction heating, then the device structure is simple, but energy transfer efficiency is insufficient and excessive energy is transferred to the tool holder
Solution Approach 1:
The heating system is segmented into two separate inductors (first inductor and second inductor) that can be independently controlled. Each inductor targets specific sub-regions of the tool holder, allowing precise energy distribution to different areas based on their individual heating requirements, thereby improving overall energy transfer efficiency.
Solution Approach 2:
Different inductors are designed with different numbers of turns to provide different energy levels to different sub-regions of the tool holder. The inductor with more turns delivers higher energy to areas requiring greater heating, while the inductor with fewer turns delivers appropriate energy to areas requiring less heating, optimizing local energy efficiency.
2Manufacturing precision
If inductors with adjustable spacing are used to adjust the singular point position of the induction magnetic field, then heating precision is improved, but mechanical complexity increases
Solution Approach 1:
The mechanical adjustment system for inductor spacing is replaced with an electrical control system. By independently controlling the activation and energy output of each inductor through the electrical supply unit, the position of the singular point of the induction magnetic field is adjusted electrically rather than mechanically, eliminating complex mechanical adjustment mechanisms while maintaining heating precision.
Solution Approach 2:
The system achieves dynamic adjustment of the magnetic field singular point position through temporal control of the inductors. The electrical supply unit can activate each inductor at different times and with different energy levels, dynamically shifting the heating focus without any physical movement of the inductors themselves.
3Productivity
If excessive energy is transferred to the tool holder during shrink fit clamping, then heating effectiveness is improved, but tool holder service life is reduced
Solution Approach 1:
The heating energy is distributed non-uniformly across different sub-regions of the tool holder based on their specific requirements. Each inductor is designed with appropriate turns to deliver the exact energy needed for its targeted area, avoiding excessive energy transfer to any single region and preventing damage that would reduce service life.
Solution Approach 2:
The system monitors the heating process and controls the energy output of each inductor independently through the electrical supply unit. This feedback control ensures that each sub-region receives the precise amount of energy required for effective heating without exceeding the thermal tolerance of the tool holder material, thereby maintaining service life.
4Loss of energy
If two inductors with different numbers of turns are used to deliver different energies to different sub-regions, then energy transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The control system is segmented into independent control channels for each inductor through the electrical supply unit. Each inductor can be activated and deactivated independently, and their energy output can be individually adjusted based on the specific heating requirements of their targeted sub-regions, achieving efficient energy transfer with a relatively simple control architecture.
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 achieves significant energy savings (up to 25%), improved heating precision, reduced mechanical complexity, and extended tool holder lifespan by concentrating energy on specific areas, enabling efficient clamping and unclamping of diverse tool holders with flexible parameter adjustments.
Implementation Method 1
an induction heating unit which comprises at least a first inductor and at least a second inductor, wherein the first inductor and the second inductor are each provided to expand at least one, in particular different, part of the tool holder during a shrinking and/or removing process by inductive heating
Implementation Method 2
expand at least one, in particular different, part of the tool holder during a shrinking and/or removing process by inductive heating
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to an induction heating device (52a-h) for shrinking tools (10a-h) into and/or out of tool holders (12a-h) with an induction heating unit (14a-h) comprising at least a first inductor (16a-h) and at least one second inductor (18a-h), preferably designed separately from the first inductor (16a-h), wherein the first inductor (16a-h) and the second inductor (18a-h) are each provided to expand at least one, in particular different, part of the tool holder (12a-h) during a shrinking and/or out process by inductive heating, and with an electrical supply unit (20a-h).It is proposed that the inductors (16a-h, 18a-h) are designed to deliver different energies to different sub-areas (22a-h, 24a-h) of a tool holder (12a-h), which are each surrounded by the inductors (16a-h, 18a-h) in a heating operation, by having one of the inductors (16a-h, 18a-h) have more turns (26a-h) than the other inductor (16a-h, 18a-h), in particular at least 10% more turns (26a-h), and/or by having the electrical supply unit (20a-f) at least designed to operate the first inductor (16a-f) and the second inductor (18a-f) differently.