Empt Coil With Exchangeable Conductor Regions
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Solution Overview
Problem
Pulse welding coils suffer from rapid fatigue and shortened lifetime due to high mechanical and thermal stresses in regions of high current density, limiting their effectiveness and requiring costly and complex solutions for extended use.
Innovation Solution
The coil design features detachable regions of high current density, allowing for easy replacement when fatigued, while the remainder of the coil, with lower current density, maintains a longer lifespan and can continue operation with minimal downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the coil is designed with narrow bridges to concentrate current flow and achieve high current density, then the field strength and forming capability are improved, but the mechanical stress and thermal stress on the coil material increase, leading to rapid fatigue and shortened lifetime
Solution Approach 1:
The coil is divided into two distinct parts: a narrow bridge region that generates the high current density needed for forming, and a wider support region that provides mechanical strength and heat dissipation. This segmentation allows each part to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different regions of the coil are given different cross-sectional areas to match their functional requirements. The bridge region has narrow cross-section for current concentration, while the support regions have wider cross-sections for mechanical and thermal stability. This local quality variation resolves the contradiction between needing high current density and maintaining coil durability.
2Productivity
If the coil material is subjected to high mechanical stresses from reactive forces and thermal stresses from high current densities, then the forming capability is maintained, but the coil experiences rapid fatigue in the high current density regions
Solution Approach 1:
The coil structure is segmented into a bridge part and support parts, allowing the bridge to handle electromagnetic stresses while support regions absorb mechanical and thermal loads. This extends the overall coil service life by protecting critical regions from fatigue.
Solution Approach 2:
The coil can be constructed using composite material structures or material variations between the bridge and support regions, enabling different material properties in different areas - conductive materials optimized for electromagnetic performance in the bridge, and mechanically robust materials in the support regions.
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 design extends the operational life of pulse welding coils by enabling quick and cost-effective replacement of high-stress regions, reducing material waste and manufacturing costs, and maintaining a planar, efficient form.
Implementation Method 1
electromagnetic pulse forming/welding is a forming and/or welding process for metal workpieces, in which strong, time-variable magnetic fields induce high eddy currents in the workpiece that is to be processed
Implementation Method 2
strong, time-variable magnetic fields induce high eddy currents in the workpiece that is to be processed
Implementation Method 3
due to the coupling of the eddy currents to these inductive fields, a high force is exerted on the region of the workpiece that is to be formed
Implementation Method 4
these coils are shaped such that they comprise at least one, narrow bridge, which, when connected in series with regions of wider cross-section, effects a concentration of the current flow and thus leads to a high current density in the region of the bridge
Data Source
AI summary
An electromagnetic pulse welding coil includes a first conductive region and a second conductive region. The second conductive region is assigned to a remainder of the coil and has a low current density. The first conductive region is configured for generating a higher current density than the second conductive region. The first conductive region is detachably connected to the remainder of the coil using a detachable connection. The electromagnetic pulse welding coil is planar in design and is cut out of a metal plate.