Flexible Induction Heating Coil for Multi-Diameter Pipes
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Solution Overview
Problem
Conventional induction heating devices require multiple tools for different pipe diameters, are complex to install, and demand extensive operator training, leading to increased costs and reduced productivity in welding and brazing processes.
Innovation Solution
A flexible induction heating apparatus with a portable, multi-turn helical coil design that can accommodate various pipe diameters, featuring a turn connector to connect conductors in series and an adjustment clamp for easy installation and efficient power transfer, eliminating the need for multiple tools and extensive training.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple induction heating devices are used for different pipe diameters, then heating effectiveness is maintained, but device complexity and cost increase
Solution Approach 1:
The induction heating apparatus is designed with a flexible conductor that can be configured in multiple ways (different numbers of turns, different configurations) to accommodate various pipe diameters, making a single device universal for multiple applications rather than requiring separate tools for each diameter
Solution Approach 2:
The heating apparatus is divided into separate components (conductor, turn connector, adjustment clamp) that can be independently configured and adjusted, allowing the same basic device to be adapted for different pipe sizes through reconfiguration rather than requiring multiple complete tools
2Reliability
If conventional induction heating devices are used, then heating function is provided, but installation complexity and operator training requirements increase
Solution Approach 1:
The apparatus incorporates self-adjusting features where the flexible conductor naturally conforms to the pipe shape and the adjustment clamp provides intuitive mechanical adjustment, reducing the need for complex installation procedures and extensive operator training while maintaining reliable heating function
Solution Approach 2:
The conductor is designed to be flexible and dynamically adjustable rather than rigid and fixed, allowing it to adapt to different pipe configurations during installation without requiring complex assembly procedures or highly trained operators
3Stability of the object's composition
If fixed coil induction heating apparatus is used, then structural stability is maintained, but adaptability to different pipe diameters is reduced
Solution Approach 1:
The induction heating apparatus uses a flexible conductor instead of a rigid fixed coil, allowing the conductor to bend and conform to pipes of various diameters while maintaining structural integrity and stable heating performance through proper configuration
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 simplifies induction heating by allowing a single tool to handle multiple pipe diameters, reducing setup time and costs, and enhancing productivity by streamlining the preheating process for welders.
Implementation Method 1
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.
Implementation Method 2
Induction heating is a method for producing heat in a localized area on a susceptible metallic object. 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.
Data Source
Figure 1
Figure 2
Figure 3~4B
AI summary
Methods and apparatus for induction heating are disclosed. An example induction heating apparatus includes a first conductor and a second conductor, configured to be arranged in conformance with a workpiece while the conductors are not electrically connected in series, and a turn connector configured to: connect the first and second conductors in series to configure the first and second conductors as an inductor having a plurality of turns; and arranges portions of the first and second conductors located between the turn connector and the workpiece to be adjacent.