Alternating Current Heating With Floating Conductors for Heat Uniformity
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Solution Overview
Problem
Conventional methods for controlling heating temperature and current density distribution in alternating current heating are inefficient, leading to increased energy consumption and limited mobility of the workpiece due to conductive connections, and struggle with accurate magnetic flux control.
Innovation Solution
An alternating current heating method involving a conductive workpiece with a first and second terminal connected to a power source, a floating conductor generating proximity effect, and optionally a ferromagnetic body, to control current density and heating temperature distribution by utilizing proximity and magnetic effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conductor is provided around the workpiece to control current density distribution, then heating temperature distribution is improved, but resistance increases and energy consumption increases
Solution Approach 1:
The patent extracts the conductor from direct electrical connection to the workpiece, making it electrically floating. This removes the harmful resistance increase while preserving the beneficial proximity effect for current density control. The conductor is taken out of the electrical circuit but remains positioned to generate magnetic fields that shape current distribution.
Solution Approach 2:
The electrically floating conductor acts as an intermediary that generates magnetic fields through induced eddy currents. These magnetic fields mediate the interaction between the power source and workpiece, enabling control of current density distribution without direct electrical contact, thus avoiding resistance increase.
2Manufacturing precision
If wiring lines are used to connect workpiece and conductor, then current flow is controlled, but mobility of workpiece and conductor is limited
Solution Approach 1:
The patent extracts the electrical connection requirement from the system by making the conductor electrically floating. This eliminates the need for wiring lines to connect the conductor to the workpiece or power source, thereby enabling free movement of both components without compromising current density control.
Solution Approach 2:
The electrically floating conductor generates its own magnetic fields through induced eddy currents when exposed to the alternating current from the power source. This self-service mechanism eliminates the need for external wiring connections, allowing the conductor and workpiece to move freely while maintaining controlled current density distribution.
3Temperature
If magnetic flux derivative is used to control magnetic flux, then magnetic flux control is improved, but current density distribution control accuracy deteriorates
Solution Approach 1:
The electrically floating conductor serves as an intermediary that directly shapes current density distribution through its proximity effect. By positioning the conductor at specific locations, the current density distribution is controlled accurately without relying on complex magnetic flux derivative control, thereby improving control accuracy.
Solution Approach 2:
The patent changes the approach from controlling magnetic flux derivatives to controlling the physical position and configuration of the electrically floating conductor. This parameter change enables direct control of current density distribution through the proximity effect, achieving more accurate control results.
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
Achieves uniform current and heating temperature distribution, reducing energy consumption and enhancing workpiece mobility by controlling current density distribution and heating temperature distribution effectively.
Implementation Method 1
providing a first conductor that is electrically floating at a position that generates proximity effect at time of applying the alternating current to the workpiece
Implementation Method 2
heating at least part of the workpiece by applying the alternating current to the workpiece through the first terminal and the second terminal
Implementation Method 3
providing a ferromagnetic body near the workpiece
Data Source
AI summary
According to one embodiment, an alternating current heating method includes preparing a conductive workpiece, attaching a first terminal and a second terminal connected to a power source, which is capable of supplying alternating current, to the workpiece, providing a first conductor that is electrically floating at a position that generates proximity effect at time of applying the alternating current to the workpiece, and heating at least part of the workpiece by applying the alternating current to the workpiece through the first terminal and the second terminal.