Flexible Induction Coil Carrier for Pipe Welding Adaptability
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Solution Overview
Problem
Existing devices for inductively welding thermoplastic jacket pipes to steel pipes in district heating systems are not adaptable to varying nominal diameters, leading to impractical solutions for different pipe sizes.
Innovation Solution
The electrical conductors of the induction coil are embedded in a flexible carrier strip with excess length, which is clamped off using loop clamps to adjust the effective circumference, allowing for easy adaptation to different sleeve diameters while minimizing magnetic field losses and enabling a separate measurement winding for monitoring the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a link chain carrier with fixed-length induction coil turns is used, then the device is simple to operate, but it cannot be adapted to different sleeve diameters
Solution Approach 1:
The patent applies the dynamics principle by making the carrier strip flexible and adjustable in length. The induction coil turns are arranged on a flexible carrier strip that can be adapted to different circumferential lengths, allowing the same device to accommodate various sleeve diameters while maintaining simple operation through a standardized plug-in coupling system.
Solution Approach 2:
The patent implements parameter changes by allowing the effective length of the carrier strip to be varied. The carrier strip can be cut to different lengths or have loops of varying sizes, changing the geometric parameter of the induction coil's circumferential length to match different sleeve diameters, thus achieving versatility without complicating the operational procedure.
2Manufacturing precision
If the carrier strip length is exactly matched to the sleeve circumference, then the welding precision is optimized, but the device cannot be easily adapted to different diameters
Solution Approach 1:
The flexible carrier strip allows dynamic adjustment of the induction coil's circumferential length to precisely match different sleeve diameters. This dynamic adaptability ensures that the induction coil maintains optimal positioning and spacing for precise welding across various sizes while using a single standardized device design.
Solution Approach 2:
The patent achieves universality by designing a single carrier strip system that can serve multiple functions across different applications. By varying the length or configuring loops of the carrier strip, the same basic device structure can be adapted to weld sleeves of different nominal diameters, eliminating the need for multiple specialized tools.
3Adaptability or versatility
If loops are formed in the carrier strip for adjustment, then adaptability to different diameters is achieved, but magnetic field losses increase
Solution Approach 1:
The patent extracts or removes the problematic loop formations from the induction coil path. Instead of creating loops in the carrier strip that would generate magnetic field losses, the design uses a linear or minimally bent carrier strip configuration where the induction coil turns are closely spaced, eliminating the formation of large current loops that would cause significant energy losses.
Solution Approach 2:
The patent converts the potential harm of carrier strip bending into a benefit by carefully designing the bend radius and spacing. Where bends are necessary for adaptation, they are designed to be gradual and tight, transforming what could be significant magnetic field disruptions into minimal losses, and the flexible carrier strip itself becomes the mechanism for achieving both adaptability and efficiency.
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 allows for reliable and efficient welding across various pipe diameters with reduced energy losses and provides a means to monitor the welding process through induction voltage changes, ensuring a tight connection between the thermoplastic sleeve and the steel pipe.
Implementation Method 1
a device for inductively welding the thermoplastic jacket pipe of a long-distance heating pipe with a sleeve made of thermoplastic material
Implementation Method 2
to use an induction coil enclosing the sleeve in the area of the perforated sheet metal ring to induce eddy currents, through which the perforated plate is heated
Data Source
AI summary
The sleeve (3) comprises a carrier for a split induction coil and a plug coupling (8) with two coupling sections (6,7) at the two beam ends to close the electrical conductors of the induction coil windings. The electrical conductors of the induction coil windings are embedded in a flexible carrier tape (5) so as to form a loop guided by a loop clamp (11). The carrier tape is displaceably guided within the loop clamp.