Flexible Induction Element for Uniform Large Component Heating
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Solution Overview
Problem
Existing inductive heating technologies are not cost-effective for large moving components, require component-specific inductors, and are unsuitable for slow heating over hours, leading to inefficient and uneven heating in welding processes, especially for large rotating components like pipes in plant construction.
Innovation Solution
A flexible induction device with a self-supporting induction element and coolant line that can be manually or automatically adapted to component shapes, allowing for adjustable distance and maintaining shape without additional supports, enabling efficient inductive heating of large components with medium-frequency alternating current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rigid inductors are used for rapid local heating, then welding speed is increased, but the components cannot be slowly heated over hours and the inductors are not suitable for large rotating components
Solution Approach 1:
The patent applies the dynamics principle by making the inductor flexible rather than rigid. The flexible inductor can adapt to different component shapes and sizes, allowing it to be used for both rapid local heating during welding and slow heating over hours. The flexibility enables the inductor to conform to large rotating components while maintaining effective coupling for heat transfer.
Solution Approach 2:
The patent implements parameter changes by allowing the inductor to operate across a wide range of heating rates. The same flexible inductor can be used for rapid heating (high power, short duration) during welding operations or for slow heating (lower power, extended duration) for stress relief or preheating applications, changing the operational parameters rather than requiring different inductors.
2Manufacturing precision
If component-specific rigid inductors are manufactured, then heating precision is improved, but costs increase considerably
Solution Approach 1:
The patent applies universality by designing a single flexible inductor that can be used for multiple component types and sizes. Instead of manufacturing separate rigid inductors for each component geometry, the flexible inductor can be configured to fit various shapes and dimensions, achieving heating precision for different applications without increasing manufacturing costs.
Solution Approach 2:
The patent utilizes flexible shells by employing a flexible inductor structure that can be bent and shaped to conform to different component geometries. This flexibility allows the same inductor to adapt to various component-specific requirements while maintaining effective electromagnetic coupling for precise heating, eliminating the need for expensive custom-rigid inductor manufacturing.
3Use of energy by moving object
If inductors are placed close to components for rapid heating, then heating efficiency is improved, but the inductors get very hot and are not suitable for slow heating
Solution Approach 1:
The patent implements parameter changes by allowing the inductor to operate at different power levels and durations. For rapid heating, high power is applied for short periods with close coupling. For slow heating applications, lower power is applied over extended periods, allowing the inductor to dissipate heat more effectively and operate at lower temperatures, preventing overheating while maintaining heating 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
Enables cost-effective, uniform, and controlled heating of large components, including pipes, at slow heating rates, without the need for component-specific inductors, reducing energy losses and preventing unwanted temperature peaks, suitable for preheating, welding, and post-welding annealing.
Implementation Method 1
Eddy currents are induced in the components in the area of the weld seam in front of the actual welding device by means of a device called an inductor, which lead to resistance heating
Implementation Method 2
Eddy currents are induced in the components in the area of the weld seam in front of the actual welding device by means of a device called an inductor, which lead to resistance heating
Implementation Method 3
a cooled flexible induction element with a flexible coolant line for a coolant to cool the induction element
Implementation Method 4
a flexible coolant line for a coolant to cool the induction element
Data Source
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AI summary
The invention relates to a device (10) for inductively heating metal components (15), in particular during welding, comprising at least one flexible induction element (12) and at least one flexible coolant line (12) for a coolant for cooling the induction element, wherein the flexible induction element and the coolant line can be plastically or elastically deformed several times and can be manually or automatically adapted to the shape of components to be heated in such a way that a distance remains between the induction element and coolant line and the components to be heated, wherein the flexible induction element and the coolant line are designed in such a way that the induction element and the coolant line maintain said shape in a self-supporting manner during the operation of the device.