Flexible Induction Heating Cable for Multi-Diameter Pipe Welding
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Solution Overview
Problem
Conventional induction heating systems for welding and brazing require multiple tools for different pipe diameters, are complex to install, and demand operator expertise, leading to increased costs and reduced productivity.
Innovation Solution
A portable, flexible induction heating tool with a multi-turn helical coil design that can accommodate various pipe diameters, simplifying installation and operation by using a single induction heating assembly with a turn connector and adjustment clamp to ensure efficient power transfer without the need for extensive training or multiple tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple induction heating tools are used for different pipe diameters, then heating effectiveness for various pipe sizes is improved, but device complexity and cost increase
Solution Approach 1:
The induction heating tool is designed with a universal heating blanket that can accommodate multiple pipe diameters through a single device. The blanket includes conductors arranged in a configuration that can be adapted to different pipe sizes, eliminating the need for multiple specialized tools for different diameter ranges.
Solution Approach 2:
The heating blanket is designed with flexible conductors that can be dynamically adjusted and wrapped around pipes of varying diameters. The conductors can be repositioned and reconfigured to match different pipe sizes, providing adaptability without requiring multiple fixed-tools.
2Reliability
If conventional induction heating systems are used, then heating capability is achieved, but installation complexity and operator training requirements increase
Solution Approach 1:
The induction heating system is designed to be self-configuring through the turn connector assembly, which automatically establishes the proper electrical connections when the blanket is wrapped around the pipe. The system guides the operator through simple steps without requiring extensive training on complex electrical configurations.
Solution Approach 2:
The heating blanket is divided into modular sections with conductors that can be independently connected through the turn connector. This segmentation allows for simplified installation where each section can be independently positioned and connected, reducing overall installation complexity.
3Manufacturing precision
If custom cable wraps are required for each pipe diameter, then precise heating control is improved, but installation time and productivity are reduced
Solution Approach 1:
The conductors in the heating blanket are pre-arranged in optimal configurations for different pipe diameters during manufacturing. The turn connector is pre-designed to facilitate quick connection, eliminating the need for operators to perform complex cable wrapping and configuration during installation.
Solution Approach 2:
The system maintains heating precision across different pipe diameters by allowing the operator to change physical parameters such as the number of turns and conductor spacing through simple mechanical adjustments rather than requiring custom cable wraps for each diameter.
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 heating of pipes with different diameters using a single tool, reducing tooling costs, simplifying installations, and improving welder productivity by eliminating the need for custom cable wraps and extensive operator training.
Implementation Method 1
Induction heating involves applying an AC electric signal to a heating loop or coil placed near a specific location on or around the metallic object to be heated. The varying or alternating current in the loop creates a varying magnetic flux within the metal to be heated. Current is induced in the metal by the magnetic flux, thus heating it.
Data Source
AI summary
Methods and apparatus for induction heating are disclosed. An example induction heating cable assembly includes: a first group of one or more cables extending substantially in parallel; a second group of one or more cables extending substantially in parallel, the first group of cables in parallel with the second group of cables; and an insulation layer configured to insulate the first group of cables and the second group of cables from electrical contact, the insulation layer configured to group the first group of cables, to group the second group of cables, and to extend between the first group and second groups of cables, in which the first group of cables, the second group of cables, and the insulation layer are conformable to enable conformance of the induction heating cable assembly to a workpiece to be heated via the induction heating cable assembly.