High Frequency Power Supply with Variable Reactors for Load Matching
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Solution Overview
Problem
High frequency power supply systems for forge welding or annealing processes face challenges in maintaining a closely regulated output due to dynamically changing load characteristics, which affects the heating efficiency and consistency in induction or resistance welding applications.
Innovation Solution
The implementation of a high frequency electrical heating system that includes a solid state inverter and a load matching and frequency control apparatus using pairs of variable reactors with geometrically-shaped moveable insert cores and stationary split-bus sections, allowing for adjustable inductance to maintain a constant heating current and frequency, along with capacitors to achieve maximum power transfer and resonance at the desired operating frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If variable reactors are used to match load impedance in high frequency power supply systems, then power transfer efficiency is improved, but output regulation precision deteriorates due to dynamically changing load characteristics
Solution Approach 1:
The patent applies dynamics by making the reactor inductance variable rather than fixed. The reactor inductance is dynamically adjusted to match the changing load characteristics during the heating process, allowing the system to maintain optimal power transfer efficiency while compensating for load variations. This is achieved through a variable reactor design where the inductance can be changed during operation to adapt to dynamically changing load conditions.
Solution Approach 2:
The patent changes the inductance parameter of the reactor to optimize system performance. By varying the reactor inductance value according to load conditions, the system achieves both efficient power transfer and improved output regulation. The inductance parameter is adjusted to match the dynamic impedance characteristics of the heating load, resolving the contradiction between efficiency and precision.
2Device complexity
If fixed inductance reactors are used in load matching apparatus, then device complexity is reduced, but adaptability to varying load characteristics deteriorates
Solution Approach 1:
The patent transforms the static reactor design into a dynamic one by enabling variable inductance adjustment. This allows the reactor to adapt to different load conditions without requiring multiple fixed reactors or complex switching networks. The variable inductance capability provides adaptability while maintaining relatively simple reactor structure.
Solution Approach 2:
The variable reactor design provides universal applicability across different load conditions. A single reactor with variable inductance can match various load impedances that would otherwise require multiple specialized reactors. This multi-functionality achieves adaptability to varying load characteristics while avoiding the complexity of having separate reactors for different operating conditions.
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
This solution ensures a closely regulated output, maintaining consistent heating current and frequency, even with varying load resistances and inductances, thereby improving the efficiency and precision of the heating process in metal processing applications.
Implementation Method 1
a load matching and frequency control apparatus connected to the inverter output leads and to the means for causing the electrical heating current to flow in the portion or the portions, the load matching and frequency control network comprising: a first pair of variable reactors electrically connected in series in the inverter output leads and the load and a second pair of variable reactors electrically connected in parallel with the inverter output leads, each of the first pair of variable reactors and each of the second pair of variable reactors and producing a variable energy fields when electrically energized, the variable energy fields and the first and second pairs of variable reactors, being variable in reactance
Implementation Method 2
a geometrically-shaped moveable insert core and a stationary split-bus section with a complementary geometrically-shaped split bus section and a split-bus electric terminals for connecting the variable reactor to a circuit where the insert core section can be moved into or out of the complementary geometrically-shaped split bus section to vary the inductance of the reactor pair
Implementation Method 3
a load matching and frequency control apparatus connected to the inverter output leads and to the means for causing the electrical heating current to flow in the portion or the portions, the load matching and frequency control network comprising
Implementation Method 4
causing an electrical heating current to flow in the portion or the portions of the metal part or parts
Data Source
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AI summary
High frequency electrical heating system is provided for heating electrically conductive parts as they are advanced, either for annealing or welding processes, and in which the electrical heating current is supplied by a solid state DC to AC inverter through a load matching and frequency control circuit that maintains the desired load current and frequency with changes in the load impedance caused by the electrically conductive parts as they are advanced. Load matching is achieved with high frequency variable reactors having a geometrically-shaped moveable insert core section and a stationary split-bus section with a complementary geometrically-shaped split bus section and a split electric terminal bus section where the insert core section can be moved relative to the stationary split-bus section to vary the inductance of the reactor pair.