Electric Heating Device Radiant Tube Protective Insert

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Solution Overview

Problem

Electric heating devices with radiant tubes and heating elements suffer from element failure due to thermal expansion, ageing, and overloading, leading to wire breaks, electrical arcs, and potential burning through of the radiant tube, necessitating reduced power output to avoid damage.

Innovation Solution

Incorporating a protective insert of electrically conductive material between the radiant tube and heating element to redirect molten metal and electrical arcs, allowing for higher power usage while minimizing damage and facilitating easy replacement of failed components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the heating device operates at high power, then the heating efficiency is improved, but the risk of element failure and radiant tube damage increases

Engineering Contradiction:

Improvepower outputVSAvoidelement failure risk

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

A protective insert made of electrically conductive material is introduced as an intermediary component between the heating element and the radiant tube. This insert acts as a sacrificial protective layer that intercepts molten metal and electrical arcs during element failure, preventing direct damage to the radiant tube. The protective insert is positioned to receive falling molten metal and conduct away electrical arcs, thereby enabling higher power operation while maintaining system reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If the heating device operates at high power, then the heating efficiency is improved, but the risk of radiant tube damage from molten metal and electrical arcs increases

Engineering Contradiction:

Improvepower outputVSAvoidmolten metal damage

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The protective insert is designed to exploit the harmful effects of molten metal and electrical arcs by positioning itself to intercept these dangerous factors. The electrically conductive material of the insert allows it to conduct electrical arcs away from the radiant tube, while its physical presence catches falling molten metal. This converts what would be destructive forces into controlled phenomena that protect the radiant tube, enabling higher power operation without compromising the tube's integrity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If safety margins are increased to prevent element failure, then the reliability is improved, but the power output is reduced

Engineering Contradiction:

Improvesafety marginVSAvoidpower output

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The protective insert is installed in advance within the radiant tube, positioned to intercept molten metal and electrical arcs before they can reach the radiant tube wall. This preliminary protective measure ensures that when element failure occurs, the damage is contained within the insert rather than propagating to the radiant tube. By having this protective infrastructure pre-in place, the system can operate at higher powers without requiring excessive safety margins, as the insert provides automatic protection against failure scenarios.

Inventive Principle:

Principle #10Preliminary action

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 higher power output and reduced risk of radiant tube damage, extending the device's useful life and improving productivity by containing molten residues and arcs within the protective insert, thus reducing the need for safety margins.

Implementation Method 1

a protective insert of electrically conductive material which is arranged between the radiant tube and the electrical heating element

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

the electrical arc forms instead between the heating wire's surface failure and the protective insert

Methodology Applied

Scientific EffectElectrical arc: Electric Arc

Implementation Method 3

an electrical heating element arranged in the radiant tube where the electrical heating element comprises heating wire running in the radiant tube

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP2232945B1Electric heating device

Publication Date: 2018.04.18 SANDVIK INTELLECTUAL PROPERTY AB

Figure 1a~1b
Figure 2~3

AI summary

Electric heating device comprising a radiant tube (2) and an electrical heating element arranged in the radiant tube as well as a protective insert (10) of electrically conductive material. The protective insert (10) is arranged between the radiant tube and the electrical heating element. The device allows the use of higher element power.