Dual U-Shaped Inductor Pre-Heating for Thick Weld Edges
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Solution Overview
Problem
Existing induction pre-heating systems for welding are inefficient in heating edges of considerable thickness, leading to excessive energy consumption and non-uniform heating, with large and cumbersome pre-heating heads.
Innovation Solution
A compact induction pre-heating device with a dual U-shaped inductor configuration, supported by a sliding block structure, allows for precise and uniform heating of adjacent edges through adjustable and centered inductors, reducing energy consumption and maintaining localized heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional induction pre-heating head is used to heat edges of considerable thickness, then the edges can be heated to the required temperature, but excessive energy consumption occurs and undesired heating of the item takes place
Solution Approach 1:
The induction pre-heating head is divided into multiple independent inductors (first inductor with first and second branches, second inductor with third and fourth branches) that can be independently controlled. Each inductor targets specific regions of the edge, allowing precise energy delivery only where needed, thus reducing overall energy consumption while achieving required heating temperatures.
Solution Approach 2:
The patent implements localized heating by positioning inductor branches at different distances from the edge and controlling them independently. The first inductor heats the surface layer while the second inductor penetrates deeper, creating a graduated heating profile that concentrates energy exactly where required without overheating adjacent areas.
2Temperature
If a conventional induction pre-heating head is used to heat edges of considerable thickness, then the edges can be heated to the required temperature, but undesired heating of the item which has to be welded occurs
Solution Approach 1:
The pre-heating head is segmented into multiple inductors with independent control, allowing precise targeting of the edge region. Each inductor's magnetic field is confined to specific zones, preventing heat diffusion to adjacent unwanted areas of the workpiece.
Solution Approach 2:
Different inductor branches are positioned at varying distances from the edge to create localized heating zones. The first inductor addresses surface heating needs while the second inductor targets deeper penetration, ensuring heat is concentrated exactly where required without affecting other parts of the item.
3Reliability
If a conventional induction pre-heating head is used, then pre-heating can be performed, but the head is of large dimensions
Solution Approach 1:
The patent employs a nested inductor configuration where the second inductor is positioned within the spatial envelope of the first inductor's support structure. The first inductor's branches extend outward while the second inductor's branches are arranged inward, creating a compact multi-layered structure that maximizes heating capability within minimal space.
Solution Approach 2:
The inductors are arranged in different spatial dimensions and orientations, with branches extending in multiple directions from a compact central support. This three-dimensional arrangement allows multiple heating functions to be packed into a small footprint, maintaining full pre-heating capability while minimizing head size.
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 solution enables efficient and reliable welding by uniformly heating edges of varying thickness, reducing energy usage and improving welding reliability while maintaining localized heating.
Implementation Method 1
an induction pre-heating head heats the edges which have to be welded to a predetermined temperature
Implementation Method 2
induction pre-heating of the edges which have to be welded
Implementation Method 3
heats the edges which have to be welded to a predetermined temperature
Data Source
AI summary
Device (1) including a head (5) for induction pre-heating the adjacent edges of at least one item requiring welding which have to be joined, in which a sliding-block-shaped supporting structure (8) capable of moving above the edges to be welded (2, 3) and parallel thereto carries a first U-shaped inductor (9) in a first plane parallel to a plane containing the edges which have to be welded and carries a second inductor (14) which is U-shaped in a second plane perpendicular to the first plane in such a way that a first and second branch (16, 17) respectively of a tube (15) of the second inductor (14) are placed between the edges which have to be welded, at a predetermined distance (K) from the first inductor (9), when in use.