Field Guide Elements for Curved Workpiece Heating
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Solution Overview
Problem
Conductive heating of curved metallic workpieces, such as tubular profiles, results in inhomogeneous temperature distribution due to varying current density inside and outside bends, leading to overheating and longer heating times, which is unsuitable for high-speed series production.
Innovation Solution
The integration of compact field guide elements formed by U-shaped laminated sheets within a copper socket cooling jacket, which actively cools the laminated core, allows for precise control of current density and homogenization of temperature distribution by reducing power density inside bends, preventing overheating and improving process stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conductive heating of curved metallic workpieces is performed with alternating current, then the workpiece is heated, but the temperature distribution becomes inhomogeneous with overheating on the inside of bends
Solution Approach 1:
The patent applies local quality by placing damping devices made of magnetically conductive material specifically in the inner areas of bends where current density is highest. These localized damping devices modify the inductive resistance components only in the regions where it is needed, creating non-uniform magnetic properties in specific locations to achieve more uniform overall temperature distribution.
Solution Approach 2:
The damping devices act as intermediary elements between the alternating current field and the workpiece material. These magnetically conductive materials serve as mediators that influence the current density distribution by modifying the magnetic field characteristics in the bend areas, thereby controlling the heating pattern without direct contact with the workpiece.
2Temperature
If damping devices are cooled with cooling air or water mist, then the damping plates are protected from excessive heating, but process heat is lost and process stability decreases
Solution Approach 1:
The patent extracts the cooling function from the damping devices themselves and transfers it to a separate water-cooled support structure. The damping devices are thermally decoupled from the cooling system, allowing them to perform their magnetic function without being directly cooled. This separation eliminates the harmful cooling effect on the workpiece while still protecting the damping devices from excessive temperatures.
3Manufacturing precision
If damping devices are arranged at a distance from the workpiece, then the workpiece heating becomes more uniform, but the devices become large and bulky making position changes difficult
Solution Approach 1:
The patent applies nesting by integrating the damping devices into the support structure itself. The damping devices are mounted within or as part of the water-cooled support framework, creating a compact nested arrangement. This allows the damping devices to be positioned at the required distance from the workpiece while maintaining a compact overall structure that is easy to move and reposition.
4Temperature
If active cooling is applied to the inside of bends, then overheating is prevented, but thermal energy is actively dissipated and heating time increases
Solution Approach 1:
The patent converts the harmful effect of high current density in bend areas into a beneficial effect by using magnetically conductive damping devices. Instead of actively removing heat through cooling, the damping devices modify the magnetic field to redistribute current density, transforming the overheating problem into a controlled heating process that actually improves temperature uniformity without extending heating time.
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 solution achieves a highly stable and homogeneous heating process, enabling efficient hardening and tempering with reduced cycle times and minimizing thermal energy loss, suitable for automated series production.
Implementation Method 1
copper socket cooling jacket, which actively cools the laminated core
Implementation Method 2
cooling medium, in particular water, flowing through the cooling jacket
Implementation Method 3
laminated magnetic cores made of transformer plates... to influence the inductive resistance components in the current paths
Implementation Method 4
influence the inductive resistance components in the current paths and thus make the workpiece heating more uniform
Implementation Method 5
conductive heating of curved metallic workpieces... with alternating current... the current density is greater on the inside of a bend than on the outside
Data Source
Figure 1~2
AI summary
In a method for the conductive heating of elongated, simply or multiply curved metallic workpieces, particularly pipe profiles, specially designed field guide elements are used to homogenize the temperature distribution within the workpiece. These elements are arranged opposite the inner curvature surfaces of the workpiece during heating, without contact. The field guide elements are formed from U-shaped sheets welded together to form a stack. The stack of sheets is housed within a casing that forms a cooling jacket, through which a cooling medium, particularly water, flows to cool the stack of sheets.Field guidance elements designed in this way are parts of, in particular fully automated, systems for the combined hardening and tempering of workpieces with a single conduction unit or with two conduction units - one being intended for heating for hardening and the other for heating for tempering.